Singapore Airlines, one of the most ritzy airlines in the world, is partnering with a high-tech urban farm to make sure it serves the best meal on every flight. Take a look inside the futuristic operation.

Sep 18, 2019, 00:41 IST

Welcome to AeroFarms.

This high-tech, one-acre vertical farm can be found at an old steel plant in Newark, New Jersey.

The farm grows a variety of leafy greens and vegetables that will be used in dishes prepared by Singapore Airlines for its flight from Newark Airport to Singapore — the longest flight in the world.

Despite its small one-acre footprint, the farm can grow roughly 390 times as much output as a normal farm with the same acreage.

That incredible output isn't just because the crops are grown on trays stacked to the ceiling — it's because of a unique and proprietary method that AeroFarms uses, based off a technology called "aeroponics."

That incredible output isn't just because the crops are grown on trays stacked to the ceiling — it's because of a unique and proprietary method that AeroFarms uses, based off a technology called "aeroponics."

Aeroponics is a seemingly simple but cutting-edge growing process.

It uses a mist of water and air to help crops grow in an environment without soil, pesticides, sunlight, or weeds. It can grow year-round, regardless of season.

It starts with a cloth-like material on which seeds are placed, and eventually roots are stored. The material is laid across trays, which are placed into the farm's growing racks.

From there, the farm uses a mist of water, coupled with nutrients, to start the seeds' growth.

Instead of sunlight, the crops are exposed to LED bulbs emitting specific light spectrums, designed to discourage pests, optimize the nutrients the plants get, and even control the flavor of the plants.

Instead of sunlight, the crops are exposed to LED bulbs emitting specific light spectrums, designed to discourage pests, optimize the nutrients the plants get, and even control the flavor of the plants.

With that method, AeroFarms can grow mature, ready-to-harvest plants in a fraction of the time of a normal farm.

While baby leafy greens would normally take 30–45 days to reach maturity, AeroFarms said that it only takes AeroFarms 12–14 days.

That faster growth means that food can be supplied faster, keeping up with demand while using just a fraction of the energy.

Within just a few days, the farm will see its seeds begin to germinate...

...Begin to grow...

... Take hold in the cloth medium ...

... And grow ...

... And grow.

The farm has a variety of high-tech solutions to optimize plant growth, including computer-controlled misting...

... Temperature controls ...

... And systems that help manage the growth environment, ranging from fans, controlled air pressure between different rooms, and more.

The racks of trays resembled a server room in an office, except that each row had plants growing on it ...

... Something you typically wouldn't see around computer servers.

Sensors, controls, and backups help ensure that the plants can grow in the best conditions possible ...

... And make it easier to keep track of different crops and growing cycles.

Employees and visitors take a number of precautions to avoid accidentally interfering with the growth or contaminating the food-bound plants ...

... Including removing jewelry, entering through a series of pressurized rooms and doorways, and wearing hair nets, gowns, gloves, and more.

The farm employs about 150 people.

Once plants reach a certain point...

... They're ready to go into the food supply — including in Singapore Airlines' dishes.

Growing trays can be taken individually to the harvest room, whenever they're ready — unfortunately, we weren't able to take photos of the process ...

... And then to the packaging room ...

... Where they're packaged either for bulk delivery to clients like Singapore Airlines, or for retail.

The growing, harvesting, and packaging operation may be unique ...

... But AeroFarms is planning to expand, hoping to open additional locations.

Business Insider sampled a few different harvested greens, including baby kale, and spicy watercress.

After being packaged, the sky-bound greens are trucked to nearby Flying Food Group — the caterer that supplies Singapore's Newark flight, which is about four miles away — where they're used for the day's dishes. The airline said it would start with three appetizers, including a garden green salad, heirloom tomato ceviche, and a soy poached chicken, pictured here.

After being packaged, the sky-bound greens are trucked to nearby Flying Food Group — the caterer that supplies Singapore's Newark flight, which is about four miles away — where they're used for the day's dishes. The airline said it would start with three appetizers, including a garden green salad, heirloom tomato ceviche, and a soy poached chicken, pictured here.

Then, the dishes are brought from Flying Food Group just down the road to Newark Airport, where they're loaded onto the plane.

If you're interested in trying AeroFarms' produce and you're located in the New York City metropolitan area, the farm sells packaged goods in local grocery stores under the brand name Dream Greens.

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Singapore Airlines, one of the most ritzy airlines in the world, is partnering with a high-tech urban farm to make sure it serves the best meal on every flight. Take a look inside the futuristic operation.

Welcome to AeroFarms.

This high-tech, one-acre vertical farm can be found at an old steel plant in Newark, New Jersey.

The farm grows a variety of leafy greens and vegetables that will be used in dishes prepared by Singapore Airlines for its flight from Newark Airport to Singapore — the longest flight in the world.

Despite its small one-acre footprint, the farm can grow roughly 390 times as much output as a normal farm with the same acreage.

That incredible output isn't just because the crops are grown on trays stacked to the ceiling — it's because of a unique and proprietary method that AeroFarms uses, based off a technology called "aeroponics."

Aeroponics is a seemingly simple but cutting-edge growing process.

It uses a mist of water and air to help crops grow in an environment without soil, pesticides, sunlight, or weeds. It can grow year-round, regardless of season.

It starts with a cloth-like material on which seeds are placed, and eventually roots are stored. The material is laid across trays, which are placed into the farm's growing racks.

From there, the farm uses a mist of water, coupled with nutrients, to start the seeds' growth.

Instead of sunlight, the crops are exposed to LED bulbs emitting specific light spectrums, designed to discourage pests, optimize the nutrients the plants get, and even control the flavor of the plants.

With that method, AeroFarms can grow mature, ready-to-harvest plants in a fraction of the time of a normal farm.

While baby leafy greens would normally take 30–45 days to reach maturity, AeroFarms said that it only takes AeroFarms 12–14 days.

That faster growth means that food can be supplied faster, keeping up with demand while using just a fraction of the energy.

Within just a few days, the farm will see its seeds begin to germinate...

...Begin to grow...

... Take hold in the cloth medium ...

... And grow ...

... And grow ...

... And grow.

The farm has a variety of high-tech solutions to optimize plant growth, including computer-controlled misting...

... Temperature controls ...

... And systems that help manage the growth environment, ranging from fans, controlled air pressure between different rooms, and more.

The racks of trays resembled a server room in an office, except that each row had plants growing on it ...

... Something you typically wouldn't see around computer servers.

Sensors, controls, and backups help ensure that the plants can grow in the best conditions possible ...

... And make it easier to keep track of different crops and growing cycles.

Employees and visitors take a number of precautions to avoid accidentally interfering with the growth or contaminating the food-bound plants ...

... Including removing jewelry, entering through a series of pressurized rooms and doorways, and wearing hair nets, gowns, gloves, and more.

The farm employs about 150 people.

Once plants reach a certain point...

... They're ready to go into the food supply — including in Singapore Airlines' dishes.

Growing trays can be taken individually to the harvest room, whenever they're ready — unfortunately, we weren't able to take photos of the process ...

... And then to the packaging room ...

... Where they're packaged either for bulk delivery to clients like Singapore Airlines, or for retail.

The growing, harvesting, and packaging operation may be unique ...

... But AeroFarms is planning to expand, hoping to open additional locations.

Business Insider sampled a few different harvested greens, including baby kale, and spicy watercress.

Then, the dishes are brought from Flying Food Group just down the road to Newark Airport, where they're loaded onto the plane.

If you're interested in trying AeroFarms' produce and you're located in the New York City metropolitan area, the farm sells packaged goods in local grocery stores under the brand name Dream Greens.