Green Automation’s fully automated growing system is specifically optimized for the production of cut leafy greens, herbs, and small head lettuces intended for sale in cut form. From substrate filling and sowing to harvesting and mixing, the entire process is carried out without human contact, ensuring the cleanest, safest, and freshest produce possible.
This system automates virtually every phase of production, from seeding to harvesting, dramatically reducing labor costs and increasing operational efficiency. But the benefits go beyond productivity—quality takes a significant leap forward.
Because routine tasks are fully automated, workers rarely enter the greenhouse, minimizing the risk of contamination. Only the grower periodically checks the biological status of the crops, ensuring optimal growing conditions while maintaining a high level of biosecurity.
The result is a high-performance, low-touch growing environment that delivers consistent, high-quality leafy greens with minimal labor and maximum control.
The production of lettuces and herbs begins with substrate or medium filling. Green Automation’s patented open gutter system is automatically filled with a continuous strip of growing substrate, while more conventional boxed gutters are filled with pots or plugs. Our systems typically use peat or rockwool, though we are actively researching alternative substrates that offer additional benefits to growers.
We offer several system configurations tailored to the type of growing medium—whether solid (like rockwool) or loose (like peat)—to ensure optimal performance and flexibility.
Once the medium is in place, the sowing machine seeds directly into the gutters. The plants remain in the same gutter throughout the entire growing cycle—no transplanting required. This streamlined process reduces labor and minimizes plant stress.
A typical sowing line includes:
These seeders are custom-designed to work seamlessly with our gutter systems, ensuring precise seed placement. The continuous substrate strip allows for customized seed spacing—adaptable by variety or even by individual growing line—giving growers full control over plant density and yield optimization.
The germination phase marks the beginning of the growing cycle. During this stage, gutters are automatically moved through a dedicated germination area, where environmental conditions are carefully controlled to ensure optimal seed sprouting.
To maximize space efficiency, Green Automation has developed a lower-level germination zone, located beneath the main growing lines. Once germination is complete, an automated elevator system lifts each gutter to the upper growing line, seamlessly transitioning it into the next phase of growth. Depending on the greenhouse layout and system configuration, the germination area may also be positioned at the same level as the main growing line.
A recent innovation includes germination towers, strategically placed in the processing area before the greenhouse—offering even greater flexibility and space optimization.
Regardless of the setup, the germination area is typically enclosed and climate-controlled, with precise regulation of temperature and humidity to support uniform and healthy germination.
Once seeds have successfully germinated, the gutters are automatically transferred to the growing lines inside the greenhouse. To maximize space utilization, some systems feature an optional lower level specifically designed for young plant development. Alternatively, plants can be moved directly to the upper level, where they begin absorbing natural sunlight and continue their growth cycle.
Green Automation offers flexible solutions for young plant growing, tailored to the specific needs of your crop—whether you’re cultivating baby leaf, teen leaf, or head lettuce varieties.
Not sure which setup is right for you? Reach out to our team—we’ll help you find the perfect configuration to grow your plants efficiently and profitably.
As the plants mature, the gutters automatically move through the greenhouse toward the harvesting area. During this journey, the spacing between gutters is dynamically adjusted to match the plants’ growth stage. This ensures each plant receives the space it needs—no more, no less—maximizing greenhouse efficiency.
This automated spacing system is a key driver of high plant density and productivity. By giving plants just the right amount of room at each phase, growers achieve unmatched space utilization and consistent yields.
Our continuous growing medium gutters allow for flexible seed positioning, enabling precise spacing tailored to each crop variety or growing line. This adaptability ensures optimal use of greenhouse space and supports efficient, high-yield production.
For systems using boxed gutters, a transplanting step may be included to accommodate different growing strategies.
When the leafy greens are ready for harvest, the system automatically transports the gutters via a series of conveyor belts to either a manual harvesting station or a fully automated harvester.
For operations requiring mixed greens, the automated harvester can be equipped with a mixing system, allowing for precise blending of different varieties. This intelligent mixing capability simplifies production planning and eliminates unnecessary movements within the greenhouse—streamlining operations and increasing efficiency.
Each gutter is individually cut to ensure optimal cutting precision and a minimal waste rate. This targeted approach helps maintain product quality while maximizing yield.
After harvesting, each empty gutter is automatically routed through a multi-step cleaning process to prepare it for the next growing cycle.
Substrate Removal
The majority of the used substrate is removed and transported to a designated waste container.
Residue Cleaning
Remaining particles and fine residues are cleared using compressed air and water jets, ensuring a thorough clean.
Water Wash
Gutters are then washed with hot or cold water, depending on system settings and hygiene requirements.
Optional Sanitation
For operations requiring the highest level of cleanliness, an optional sanitation step can be added to ensure the gutters are completely pristine and ready for reuse.
This automated cleaning sequence ensures consistency, hygiene, and operational efficiency, reducing downtime and labor while maintaining optimal growing conditions.
After the gutters are cleaned, they are temporarily stored in a buffer zone between the harvesting and sowing processes. This buffer adds operational flexibility, allowing harvesting and sowing to run independently without requiring perfect synchronization.
The buffer also provides time for the gutters to dry completely, ensuring optimal conditions before the next growing cycle begins.
The size and configuration of the buffer are customized to meet the specific operational needs of each grower, helping maintain a smooth and efficient workflow throughout the greenhouse.
Green Automation’s control system ensures that plants receive the precise amount of water and nutrients they need—automatically and efficiently.
Water is delivered to the gutters via drip emitters, providing targeted irrigation. Any excess water flows into return tanks, which are efficiently positioned beneath the growing lines to save space and streamline the system.
This smart irrigation setup guarantees optimal hydration and nutrient delivery for every plant. Unused water is collected, filtered, and recirculated, significantly reducing waste. Our robust filtration system maintains the highest water quality, ensuring healthy and safe leafy greens.
By using a hydroponic NFT system and recirculating irrigation water, our solution can reduce water consumption by up to 95% compared to traditional open-field farming—making it both environmentally and economically sustainable.
