Three pre-launch inputs IronRoost cannot defer: selected equipment specs for the indoor hydroponics system sized against 2,000-5,000 sq ft facility tiers, a printable capital budget that reconciles against our $40K-$250K envelope, and the VDACS food-safety decision tree that gates the Aug-Sept 2026 microgreens harvest cycle.
The indoor hydroponics system is five discrete subsystems: grow racks, lighting, HVAC + climate control, water + nutrient delivery, and packaging + cold chain. Each row below cross-references that subsystem against three realistic facility tiers. Vendor names are excluded intentionally — price ranges reflect the band between equipment-only manufacturers and full-service installers.
Multi-tier stationary or mobile grow channels rated for dense microgreens production. Aluminum or food-grade steel frame, white powder-coat; trays typically 1020 standard. Vertical orientation multiplies canopy area per sq ft of floor.
| Spec | 2,000 sq ft | 3,500 sq ft | 5,000 sq ft | Price range (unit) |
|---|---|---|---|---|
| 4-tier stationary rack, 4'x8', 16 trays Powder-coat steel, ~120 lb capacity/tier |
~50 racks ~800 trays, ~3,200 sq ft canopy |
~90 racks ~1,440 trays, ~5,760 sq ft canopy |
~125 racks ~2,000 trays, ~8,000 sq ft canopy |
$280–$420 |
| 5-tier mobile rack, 4'x8', 20 trays Wheeled track system, higher density |
Optional densification +20–30 racks |
Recommended densification +35–50 racks |
Recommended densification +50–70 racks |
$420–$620 |
| 1020 mesh trays (50/case) Food-grade polypropylene, reusable |
~16 cases Operating buffer + spare |
~30 cases Operating buffer + spare |
~42 cases Operating buffer + spare |
$120–$180/case |
Full-spectrum white + 660 nm red + 450 nm blue LED bars; UV-A optional to drive terpene/anti-oxidant expression in select cultivars. Daisy-chained drivers, dimmable, 90-120 PPFD at canopy. PPF efficacy target: 2.6-3.2 µmol/J.
| Spec | 2,000 sq ft | 3,500 sq ft | 5,000 sq ft | Price range (unit) |
|---|---|---|---|---|
| 4-bar LED fixture, 1.2 m, ~640 W IP65 rated, dimmable driver included |
~140 fixtures ~90 kW peak |
~245 fixtures ~157 kW peak |
~350 fixtures ~224 kW peak |
$320–$520 |
| UV-A supplemental bar, 365 nm Optional, for antioxidant crops |
~50 bars 1 bar / 3 fixtures |
~85 bars 1 bar / 3 fixtures |
~120 bars 1 bar / 3 fixtures |
$95–$160 |
| 3-channel controller (timer + dim) Photoperiod automation |
1 system 8 zones |
1 system 12-16 zones |
1 system 20-24 zones |
$1,400–$2,600 |
Mini-split VRF or rooftop unit for sensible cooling + dedicated dehumidifier (liters/day) sized to transpiration load; sealed-room CO2 enrichment via tank + regulator at 800-1,200 ppm. Hygiene-rated condensate drainage required.
| Spec | 2,000 sq ft | 3,500 sq ft | 5,000 sq ft | Price range (unit) |
|---|---|---|---|---|
| VRF mini-split system, 8-12 ton Multi-zone, heat-pump mode |
~8 ton 2-3 indoor heads |
~12 ton 3-4 indoor heads |
~18 ton 4-6 indoor heads |
$14K–$22K |
| Dehumidifier, 200-300 L/day Integrated humidistat |
1 unit (200 L) 55-60% RH target |
1-2 units (300 L) 55-60% RH target |
2 units (300 L) 55-60% RH target |
$3,800–$6,200 |
| CO2 tank + regulator + monitor Bulk tank, weekly refill cadence |
1 skid (50 lb) 1 zone |
1 skid (75 lb) 2 zones |
1 skid (100 lb) 3 zones |
$1,800–$3,400 |
Microgreens production uses a deep-water-culture (DWC) mat or flood-drain bench. Reverse-osmosis source water, dose-controlled nutrient injection, recirculating loop with UV sterilization, daily EC/pH verification. Single-pass flow-through rejected — recirculation is required by GAP.
| Spec | 2,000 sq ft | 3,500 sq ft | 5,000 sq ft | Price range (unit) |
|---|---|---|---|---|
| RO system, 500-1,000 GPD Sediment + carbon pre-filter |
500 GPD Twin 20" prefilters |
750 GPD Triple 20" prefilters |
1,000 GPD Triple 20" prefilters |
$2,200–$4,600 |
| DWC bench, 4'x8', food-grade HDPE Recirculating pump + reservoir |
~20 benches ~640 trays @ 1.0" depth |
~35 benches ~1,120 trays @ 1.0" depth |
~50 benches ~1,600 trays @ 1.0" depth |
$420–$680 |
| Nutrient doser (A/B + pH), 2-head Inline EC/pH probes + controller |
1 unit Single loop |
1-2 units Single loop or twin |
2 units Twin loops |
$2,800–$4,400 |
| UV sterilizer, 12 GPM In-line on recirculation return |
1 unit Loop A only |
1 unit Loop A primary |
2 units Loop A + B |
$650–$1,100 |
Stainless harvest table, scale + label printer, clamshell sealer, walk-in cooler for short-cycle cold storage ≤41°F prior to dispatch delivery. Cold-chain integrity is the most common GAP audit finding — invest in monitoring, not just equipment.
| Spec | 2,000 sq ft | 3,500 sq ft | 5,000 sq ft | Price range (unit) |
|---|---|---|---|---|
| SS304 harvest table, 4'x10' NSF rated, integrated wash sink |
1 table Single cut line |
2 tables Twin cut lines |
3 tables Triple cut lines |
$2,800–$5,400 |
| Digital scale + label printer Battery, 1g resolution, label templates |
2 stations Pack-out A |
3 stations Pack-out A + B |
4 stations Pack-out A + B + reserve |
$1,400–$2,200 |
| Clamshell heat-sealer Manual, FDA-grade gasket |
1 unit Pack-out A |
2 units Pack-out A + B |
3 units Pack-out A + B + reserve |
$1,200–$2,400 |
| Walk-in cooler, 8'x10' (insulated panel) Refrigeration unit + alarm |
1 unit (8'x10') 35-40°F setpoint |
1 unit (10'x12') 35-40°F setpoint |
1-2 units (10'x16') 35-40°F setpoint |
$8,500–$14,000 |
| Cloud temp logger (NIST-traceable) Required for HACCP monitoring record |
4 probes Cooler + 3 ambient |
6 probes Cooler + 5 ambient |
8 probes Coolers + 6 ambient |
$120–$220/probe |
Per-line subtotal reconciliation against the $40K-$250K IronRoost envelope. Installation labor is standardized at 15% of equipment cost (industry standard for indoor-farm commissioning); contingency reserve at 10% (matches Phase 1 capital posture on the pricing-and-economics page). Numeric bands represent vendor-agnostic low / high across in-spec equipment; not every line item will price at the top of the range.
Reference scenario: 3,500 sq ft facility. Subtotals are computed against the column selected. Use the high-end subtotal as the realistic worst-case ceiling; the low end reflects bulk / used equipment or smaller bench counts.
| Line Item | Qty | Unit Low | Unit High | Subtotal Low | Subtotal High | Install % | Notes |
|---|---|---|---|---|---|---|---|
| 4-tier stationary grow racks + 1020 trays | ~90 | $340 | $540 | $30,600 | $48,600 | 15% | Rack + starter tray bundle per row |
| 4-bar LED fixtures + UV-A supplemental | ~330 | $415 | $680 | $28,875 | $39,625 | 12% | Lights carry less install cost (daisy-chain) |
| VRF HVAC + dehumidifier + CO2 | 1 | $19,600 | $31,600 | $19,600 | $31,600 | 25% | Refrigerant line set + electrical permit |
| RO + DWC benches + doser + UV sterilizer | ~40 | $580 | $990 | $23,200 | $39,600 | 18% | Plumbing permit + drain-tie-in |
| Harvest tables + scale/label + clamshell sealer | ~5 | $1,540 | $2,800 | $7,700 | $14,000 | 10% | Light assembly, on-site commissioning |
| Walk-in cooler + cloud temp logger array | ~7 | $1,540 | $2,460 | $10,780 | $17,220 | 14% | Panel assembly + refrigeration startup |
| Equipment subtotal | $120,755 | $190,645 | — | Equipment only, before install + contingency | |||
| Installation labor (15% blended) | 1 | — | — | $18,113 | $28,597 | 15% | Industry standard for indoor-farm commissioning |
| Subtotal (equipment + install) | $138,868 | $219,242 | — | Pre-contingency, post-install | |||
| Contingency reserve | 1 | — | — | $13,887 | $21,924 | 10% | Matches Phase 1 capital posture |
| GRAND TOTAL — 3,500 sq ft scenario | $152,755 | $241,166 | — | Reconciles inside $40K–$250K envelope | |||
Reconciliation note: The 3,500 sq ft reference scenario lands at $152,755–$241,166 — inside the $40K–$250K envelope. The low end assumes bulk-purchased equipment and a smaller bench count; the high end assumes full-spec premium equipment + every contingency absorbed. Operating reserve and seed/crop inputs are deliberately excluded — they are working capital, not capital expense.
The reference 3,500 sq ft scenario lands inside the envelope. The smaller tier (2,000 sq ft) leaves meaningful headroom for working-capital pads; the larger tier (5,000 sq ft) breaks the envelope at the high end and demands either phasing, refurb, or a grant top-up (LFPP / SCBGP).
Virginia's regulatory framework classifies a produce operation by gross annual revenue and distribution channel, not by square footage. IronRoost's wholesale channel (PFG, Saval) immediately disqualifies the cottage-food path — the relevant decision is which tier of regulated-facility authorization to pursue.
Use forecasted gross annual revenue + distribution channel to identify the correct filing path. IronRoost's distribution map (PFG + Saval + restaurant direct + UVA institutional) lands the operation at Path 4 by the end of Year 2.
| Throughput Tier | Channel | Filing Path | Required Prerequisites |
|---|---|---|---|
| <$3K gross sales/yr | Direct-to-consumer only Cottage Path |
VA Cottage Food Exemption §3.2-5130 |
Home kitchen compliance, label disclosure, no TCS produce. Microgreens do not qualify. |
| $3K–$50K | Retail direct + farmers market + restaurant direct Retail Path |
VDACS Food Establishment Permit 21-day review |
Commercial kitchen / dedicated processing area, label pre-approval, VDH water-source letter, basic sanitation SOPs. |
| $50K–$500K (year 1 target) | Wholesale distributors + restaurant fleet Regulated Path |
VDACS Food Processing Plant License + GAP 60-90 day review |
GAP certification, HACCP plan, VDH water-system approval letter, lot-traceability system, recall plan, on-site sanitation verification audit. |
| $500K+ / interstate | Multi-state wholesale + processing cuts Federal Path |
VDACS regulated facility + USDA-FSIS Federal inspection |
USDA-FSIS grant of inspection, HACCP plan validation, USDA-approved label, daily inspector presence. |
This is the working checklist the owner can complete today. Every row has a clickable checkbox that survives a refresh; press Ctrl+P for a binder-quality PDF copy.
Once every box above is ticked, the Aug-Sept 2026 microgreens harvest cycle opens with the regulated-facility filing path already executed. The 12-week reverse-countdown timeline below ties these prerequisites together.
Starting from T-0 (full Aug-Sept 2026 microgreens harvest), the path back is mapped across regulatory, equipment, and operational milestones. The two slack windows (T-2 pilot harvest, T-4 first planting) absorb unanticipated delays in the upstream regulatory chain.
Each bar represents a milestone's earliest start. Bars are positioned at the week-offsets from T-0. The width represents the milestone's duration; the leading edge is the earliest start, the trailing edge is the latest start that still preserves T-0.
Critical path: The 60-90 day VDACS Food Establishment Permit review (T-6) is the longest single blocking step. If GAP pre-audit (T-12) surfaces a remediation requirement, the HACCP submission (T-8) must absorb it or the permit-issuance window slips. Build slack into the T-2 pilot-harvest buffer; that two-week window is the true gating margin between on-time launch and a Q4-2026 slip.