AI Sustainable Foods operates four climate-controlled 53×8×8-foot insulated reefer units on 10 acres in Saylorsburg, Monroe County, Pennsylvania — producing fish, shrimp, eggs, microgreens, mushrooms, and leafy greens year-round using closed-loop aquaponics, a 30kWh solar array, and Black Soldier Fly circular feed systems that eliminate the need for external inputs.
Our system vs. conventional farming
The following comparison is based on equivalent crop production — leafy greens, cucumbers, peppers, and herbs — in a controlled-environment setting versus conventional outdoor soil farming in the northeastern United States. Data references USDA aquaponics research and EPA agricultural water quality benchmarks.
| Factor | AI Sustainable Foods (aquaponics) | Conventional soil farming |
|---|---|---|
| Water use per lb of produce | ~0.5–1 gallon (90%+ recycled in closed loop) | ~10–20 gallons (open irrigation) |
| Synthetic fertilizers | Zero — fish waste provides all nitrogen and phosphorus | Required — applied per crop cycle |
| Pesticides / herbicides | Zero — ladybugs and system design eliminate pest pressure | Standard application schedule required |
| Watershed runoff | Zero — closed loop, no discharge to Pennsylvania waterways | Nonpoint source runoff — primary PA watershed pollutant |
| Seasonal limitation | None — climate-controlled reefers operate year-round | Seasonal — limited to growing season in PA |
| Energy source | 30kWh solar array + net-zero wood boiler | Grid-dependent machinery and irrigation pumps |
| Land use efficiency | High — vertical stacking in reefer units multiplies yield per sqft | Standard — single crop plane per field area |
| Feed input (protein production) | BSF larvae grown on-farm from food waste — 42% protein feed | Commercial feed sourced externally |
The four reefer units
Reefer 1 — Layer hens (350 birds)
The first insulated container houses our 350-bird layer hen flock in a climate-controlled environment maintained between 60–75°F year-round. The hens produce fresh eggs for community donation and local distribution. They are supplemented with Black Soldier Fly (BSF) larvae grown on-farm from food waste — a circular feed source providing 42% protein that dramatically reduces dependence on commercial feed inputs. A mobile outdoor run system rotates the flock across the property, naturally fertilizing different areas without chemical applications.
Reefer 2 — Microgreens & mushrooms
The second unit is dedicated to high-density microgreen production and log-grown mushrooms. We grow six varieties of microgreens — sunflower, pea shoots, radish, broccoli, amaranth, and cilantro — on stacked trays under LED grow lights. Mushrooms grown include oyster, shiitake, lion’s mane, and chestnut varieties, cultivated on logs harvested from our own ash, oak, and maple timber. Both products are harvested on a continuous rotation cycle for year-round availability.
Reefers 3 & 4 — Aquaponic production
Two dedicated aquaponic units form the technological core of the farm. Each operates as a closed loop: fish and shrimp produce ammonia-rich waste that nitrifying bacteria convert to nitrates, which the plants absorb as fertilizer, returning clean filtered water back to the fish. Reefer 3 produces kale, spinach, lettuce, and celery alongside fish and shrimp. Reefer 4 grows cucumbers and bell peppers — crops that require pollination — using a honeybee colony integrated with a specially designed UV and magnetic navigation system enabling effective indoor pollination year-round. Both units use vertical farming techniques to maximize yield per square foot.
The closed-loop ecosystem
Every organism and system on the farm feeds the next. Food waste from the kitchen and farm operations feeds the BSF larvae colony. The larvae feed the hens and the fish. Hen manure becomes compost. Fish waste feeds the plants. Plants filter the water back to the fish. Goats manage the vegetation on the property without herbicides. Bees pollinate the crops. Nothing leaves the system as waste.
| Input | Goes to | Output |
|---|---|---|
| Food waste | BSF larvae colony | 42% protein larval feed |
| BSF larvae | Hens + fish feed supplement | Eggs + fish growth |
| Fish waste (ammonia) | Nitrifying bacteria → plants | Natural fertilizer, clean water |
| Hen manure | Compost → soil amendment | Natural fertilizer |
| On-property timber (ash, oak, maple) | Sawmill → mushroom logs + construction + wood boiler | Mushrooms, building materials, heat |
| Solar array (30kWh) | All farm electrical systems | Zero grid dependence |
Frequently asked questions
How much water does an aquaponic system actually save?
Our closed-loop aquaponic systems recycle 90–95% of water compared to equivalent conventional soil production. For leafy greens, conventional irrigation typically requires 10–20 gallons of water per pound of produce. Our system uses approximately 0.5–1 gallon per pound because the same water circulates continuously — only topping off for evaporation losses. The EPA identifies agricultural runoff as the leading source of water quality impairment in US rivers and lakes. Our zero-runoff system addresses this directly.
What fish and crops do you produce?
Current aquaponic production includes tilapia and shrimp alongside kale, spinach, lettuce, celery, cucumbers, and bell peppers. Reefer 2 produces six microgreen varieties and four mushroom varieties continuously. Reefer 1 produces fresh eggs from 350 layer hens. All production is chemical-free and we are pursuing USDA organic certification across the entire operation.
Can this model be replicated in other communities?
Yes — that is precisely the goal. We are developing a chapter and franchise model that packages our production systems, technology stack, training, and ongoing support into a replicable turnkey unit that other nonprofits, schools, and community organizations can operate independently. Contact us to learn more about the chapter model.