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October 6, 2019

Questionnaire on Productivity of Plant Factories with Artificial Lighting (“PFALs”)

Japan Plant Factory Association (JPFA)
Research Committee on Productivity Improvement
Toyoki KOZAI, Chairman
Eri HAYASHI, Manager

The Research Committee on Productivity Improvement for PFALs intends to support PFAL operators by providing them with various indexes, definitions and methods to measure productivity. Research continued for two years from 2017 through 2018 and produced a report presenting a range of estimated index numbers as below:

Research Result: Range of estimated numbers for productivity indexes:
 No.
Resources applied 
 Range of resource productivity  Range of monetary productivity (kg/$10)  Range of production cost ($/kg) 
 1
 Electric energy
  0.11 – 0.14 kg/kWh  6.45 – 7.55  1.09 –1.28
 2
 Labor hours
  7.7 – 10.0 kg/h  5.91 - 7.0  1.18 – 1.63
 3
 Cultivation area
  0.25 - 0.33 kg/m2/d  4.82 –6.45  1.28 – 1.72
 4
 Other resources
  -  6.09–8.27  1.00 – 1.36
 
 Total
  -  1.66– 2.19  4.55 – 5.99

The Committee conducted hearings from a limited number of PFAL operators, collected information from academic papers and books on productivity and reviewed related issues in reports. We presented a certain range of productivity numbers, however, we conclude that, to help achieve greater productivity at PFALs as the group, we should collect data from more commercial PFAL operators and develop a more comprehensive and practical data library.

Therefore, we plan to expand the research target in the following order and kindly ask for your collaboration:

①PFALs related to the members of this Committee
②PFALs operated by the members of the JPFA (Japanese and non-Japanese)
③PFALs in Japan operated by non-members of the JPFA
④PFALs outside Japan operated by non-members of theJPFA
The Committee may consider starting the research to cover groups ① and ② simultaneously.


Privacy Policy
We do not disclose the names of your organization or yourself in results of the Reserach to be publicly reported nor do we disclose the list of the organizations that responded. You may always return no comment to any of the questions in this Questionnaire. The JPFA adds up the replies from all the respondents and discloses part of the data as aggregated one.

Any and all information you send shall be strictly managed by the Committee of the JPFA and used on the assumption that the production size is the same after adding up data or as that of the average of PFALs of the same or similar types or of all PFALs so that any single PFAL cannot be identified by any information provided. We plan to issue a report of the average productivity index numbers after adding up the production sizes of respective PFALs, and only to those PFAL operators who respond to this Questionnaire, we additionally provide, to the maximum extent possible without breaking confidentiality, the actual numbers of productivity indexes per the questions you answer.

【Expected report on the Questionnaire results to those who respond】
No  Resources applied  Range of resource productivity  Range of monetary productivity (kg/$10)  Range of production cost ($/kg) 
 1  Electric energy  kg/kWh    
 2  that for LED lamps  kg/kWh    
 3  that for air conditioning  kg/kWh    
 4  Labor hours  kg/h    
 5  Cultivation area  kg/m2/d    
 6  Other resources  –    
   Total  –    
Please take note of following when answering the questions:
A: Kindly comply with the productivity indexes, their definition and measurement formula as set by the Committee.
B: You may reply “blank” to any questions you find difficult to answer.
C: Actual numbers at your PFAL are much appreciated; however, the standard or planned numbers are also welcome.
D: For the produce and the period, please choose the applicable ones by circling one of the choices provided.
E: For the produce, please choose the largest one at your PFAL.
F: With respect to the categories of the produce, please refer to Figure 1.

＊This Questionnaire does not recognize sprouts and bean sprouts as PFAL grown vegetables.

        Fig. 1   Categories of the produce
Fig. 1 Categories of the produce
1.Basic Information re you/your PFAL (may keep blank if prefer)
2.If you have any comments regarding Q1. Basic Information of yours, please enter them.
3.Please choose the variety of the three largest produce in your PFAL.
＊Please assume your PFAL currently be in full operation.
Leaf Lettuce
Iceberg Lettuce
Herb
Others
No.1 Produce
No.2 Produce
No.3 Produce
4.What are the specific varieties of the three largest produce in your PFAL?

Example: Leaf Lettuce, Romain Lettuce, Baby Greens, Basil, Edible Flower....
5.What is each allocation of the cultivation tray of the three largest produce of your PFAL? (%)

Example:
  No.1 60%
  No.2 20%
  No.3 15%
6.If you have any comments regarding Q3~Q5:the three largest produce of your PFAL, please enter them.
7.Sum of the Initial Investment in PFAL (US$)
＊Including cost of interior work, air conditioning, LED lamps, cultivation trays, water pumps, etc. but excluding that of housing construction.
8.Amount of Yield (kg/month)
＊Monthly average of recent 12 months
＊Choose from: Actual value, Standard value, Planned value
＊You may sum up the yield of all of your produce variety or may assume all the cultivation trays be growing leaf lettuce. Weight is that of shipment and does not include those leaves trimmed or roots.
9.Monetary Amount of Yield of Q8 (US$/month)
＊Monthly average of recent 12 months
＊If you have any comments regarding the calculation of the monetary amount of yield and such, please also enter them.
10.Average Unit Price (US$/kg)

Example: US$ 30 /kg
11.Total Electricity Consumption of your PFAL (kWh)
＊Choose the period from the most recent 12 months, 6 months, 3 months, 1 month first and answer the total electricity consumption of your PFAL.
12.Electricity Consumption at Cultivation Room (kWh) of Q11: total Electricity Consumption of your PFAL (kWh)
＊With respect to the "cultivation room", please refer to Figure 2 below.
Fig 2. Cultivation room (colored area) defined in this questionnaire
13.Total Cost (US$) of Q11: Total Electricity Consumption of your PFAL (kWh) 

Example: US$          for            kWh
14.Labor Hours (hours)
＊Including cultivation manager
＊Excluding those for transportation
＊Choose from: most recent 12 months, 6 months, 3 months, 1 month
15.Unit Cost of Labor per hour (US$/hour)
＊Excluding plant manager 
16.Operation Rate of Cultivation Tray Area of your PFAL (%)
17.Your comments and opinions for the Questionnaire are highly appreciated!!