Unlocking Efficiency and Higher Yields with Advanced Greenhouse Automation, AI, and Climate Control Systems

Modern greenhouse production is evolving at an unprecedented pace. At the heart of this transformation is the greenhouse controller - a tool rapidly moving from a “nice-to-have” to an essential component for any grower aiming for efficiency, consistency, and profitability. However, as these systems become more sophisticated, the challenges and opportunities they present also grow.

In this new edition of Hortigen Insights, we explore what today’s greenhouse controllers can do, what they can’t, and how to choose and operate the right system for your unique needs.

Why Controllers Matter

The core purpose of any greenhouse is simple: create the best possible environment for plants, maximize yields, and minimize costs. Greenhouse controllers are the nerve center of this mission. By integrating data from an array of sensors—measuring temperature, humidity, CO₂, irrigation, and more—controllers automate complex decisions that would otherwise require constant human attention.

Benefits at a Glance:

• Automation: Simultaneously manage multiple devices and systems.
  

• Data-Driven Decisions: Generate and analyze real-time data for precise adjustments.
  

• Consistency: Achieve reliable results, crop after crop, far beyond what manual control can offer.

However, these benefits come with increased capital (CAPEX) and operational (OPEX) costs and a steeper staff learning curve. With proper setup and calibration, a modern controller can redefine what’s possible in plant cultivation.

The Operator’s Reality: Expertise Still Required

While controllers automate many tasks, they don’t eliminate the need for skilled operators. In fact, the more advanced the system, the more it demands from its users. Operators must understand:

• The specific needs of each crop at every growth stage.

• How to maintain and calibrate equipment for accurate control.

• The basics of natural science, agronomy, computer systems, bioclimatology, and meteorology.

• How can this knowledge be translated into actionable settings within the controller?

When these elements come together, the greenhouse becomes a finely tuned ecosystem in which precision and efficiency coexist.

AI and the Dream of Full Autonomy

The rise of artificial intelligence (AI) has sparked visions of fully autonomous greenhouses, where controllers manage every aspect of the environment with minimal human input. Companies like Blue Radix and Plantonomy are already pioneering these solutions.

But are we there yet? Not quite. Most current controllers still require regular configuration and oversight by skilled operators. Challenges arise when:

• There’s insufficient knowledge of the installation or agronomic principles.

• The equipment malfunctions or is poorly maintained.

• System capacity is exceeded, or sensors are not reliable.

Key Areas for Improvement:

• Sensor Cost and Reliability: Sensors remain expensive and require regular calibration.

• Redundancy: More backup sensors (drones) are needed to avoid logical errors.

• Direct Plant Sensing: Moving beyond climate variables to measure actual plant performance.

• Integrated Agronomic Intelligence: Embedding more crop-specific knowledge into controllers.

While the dream of a “set-and-forget” greenhouse is compelling, human expertise remains indispensable.

Choosing the Right Level of Automation

Not every grower needs the most advanced, AI-driven system. The optimal level of automation depends on your goals, crops, and scale.

For Basic Needs:
A basic entry-level controller (such as Link4, Maximus, or Orisha) may be sufficient to automate irrigation or ventilation. These are ideal for smaller operations or those not planning to scale up soon.

For Large-Scale or Complex Operations:
Highly automated facilities, like Vegpro’s operation in Sherrington, Quebec, use advanced controllers to optimize every production stage and reduce labor costs. These systems are particularly valuable, involving multiple crops or complex growing strategies.

Crop Diversity Matters:

• Ornamental Production: Often involves many crops with unique needs. Flexible controllers like Damatex and Argus Controls are well-suited here.
  

• Vegetable Production: Typically focuses on monocropping, where standardized equipment and controllers like Priva, Hoogendoorn, and Ridder Growing Solutions excel.

How Controllers Work: A Quick Overview

At their core, greenhouse controllers consist of two main components:

• Hardware: The physical devices that connect to sensors and equipment.
  

• Software: The “brain” that processes data and issues commands.

Controllers use analog (e.g., 0–10 VDC, 4–20 mA) and digital signals to communicate with sensors and activate equipment. Modern systems are built around programmable logic controllers (PLCs), which run advanced algorithms (often based on PID—Proportional-Integral-Derivative control) to maintain optimal conditions.

Key Features:

• Pre-set and customizable configurations for different crops and equipment.

• Real-time alerts via phone, text, or email to notify operators of anomalies.

• Remote access for monitoring and adjustments from anywhere.

Balancing Plant and Equipment Needs

A common pitfall is over-prioritizing either plant requirements or equipment efficiency.

• Focusing too much on plants: Can lead to frequent, minor adjustments that wear out equipment prematurely.

• Focusing too much on equipment: May create suboptimal conditions for plants, reducing yields and quality.

The best results come from finding a balance—using data and experience to harmonize plant health and equipment longevity.

Sunlight: The Ultimate Driver

Sunlight is the primary energy source in any greenhouse. At peak, it can deliver up to 1,000 W/m² (or 3.6 MJ/m²/h) at noon in the summer. In perspective, 1 kg of TNT contains about 4.2 MJ of energy!

Plants use this energy for photosynthesis, but excess sunlight raises greenhouse temperatures. Managing this influx—through shading, ventilation, and irrigation—is crucial. For every 1L/m² of water transpired, plants store about 2.5 MJ of energy, which is released as vapor and must be removed by dehumidification.

Data-Driven Plant Balance

For vegetable production, the daily light sum guides temperature strategies. Operators must gather plant performance indicators—such as vigor, balance, and fruit load—to fine-tune climate settings and keep crops on track.

Practical Takeaways

1. Match Investment to Need:
Don’t overinvest in features you won’t use. Choose a controller that fits your scale and complexity.

2. Work With, Not Against, Sunlight:
Build strategies that leverage natural light, rather than fighting it.

3. Protect Your Equipment:
Safeguard weather stations and controllers from lightning, water, and humidity.

4. Enable Critical Notifications:
Ensure your system can send timely alerts for rapid response.

5. Use Data Wisely:
Monitor crop performance with graphs and analytics to spot and solve problems quickly.

6. Demand Reliable Support:
Choose manufacturers and dealers who offer robust customer support, online resources, and training.

7. Learn from Experts:
Engage knowledgeable advisors to accelerate your learning curve and maximize your controller’s value.

Conclusion

Greenhouse controllers are revolutionizing how we grow, making it possible to produce more with less, even as labor becomes scarcer and climate challenges grow. But technology is only as effective as the people who use it. By choosing the right system, investing in training, and staying open to innovations, you can ensure your greenhouse is ready for the future.

For more expert insights and practical guides, visit Hortigen Insights.

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