Corn In A Cave

Farm Journal, Sep 29, 2006 by Wayne Wenzel

It's dark and cold. Why would anyone grow corn in an underground warehouse? For Doug Ausenbaugh, owner of Controlled Pharming Ventures, the atmosphere is ideal.

"Down this far underground [in an old limestone mine], it is a constant 51 [Degrees] F temperature," Ausenbaugh explains. "That makes it easier and more efficient to control the temperature of our greenhouses. Aboveground facilities have to spend much more on heating and cooling. It's also totally dark here, so we can very precisely control the amount of light the plants get regardless of time of day or season."

Ausenbaugh leases a portion of the miles-long network of tunnels and cathedral-sized rooms in the old limestone mine to grow pharma crops. The two-room plant growth chamber is a small (320 sq. ft.) but tall building. Light streams from the windows, offering a peek at a dense stand of corn.

The term "biopharming" was coined when scientists realized that plants could be genetically modified to produce pharmaceuticals. To the chagrin of some scientists, the term became a catchall for plants modified to produce not only pharmaceuticals but chemicals and materials as well.

Supporters of biopharming say these plants can provide a safe and efficient way to produce industrial chemicals, exotic polymers, life- saving vaccines and pharmaceuticals. Critics, however, say the risks far outweigh the benefits.

In the controversy, Ausenbaugh saw opportunity. A business finance specialist by trade, Ausenbaugh was not an expert in biotechnology nor growing crops. He did, however, see a solution. He took the idea of growing these plants securely underground to crop and biotechnology specialists at Purdue University and USDA.

After several presentations and meetings, Controlled Pharming Ventures received a grant for $2 million from the Indiana 21st Century Research and Technology Fund. The money was used to build a prototype and do feasibility studies in the underground Marengo, Ind., warehouse.

Several Purdue researchers continue to be involved with the project. "The first test crop planted in the underground facility produced more corn in a shorter time period than plants grown in a greenhouse on the Purdue campus," says Cary Mitchell, a Purdue horticulture professor. "We've shown that you can successfully grow crops underground in a lighted but completely contained facility. What we have here is a perfect model for controlled-environment agriculture. This could jumpstart a whole industry."

In the initial trial, genetically modified corn grown in the facility had an average yield of 337 bu./acre. By comparison, corn the researchers grew in a greenhouse yielded the equivalent of 267 bu./acre. That compares to an average U.S. corn yield of 142 bu./ acre. The higher yield in the cave links to the amount of control the researchers have over the environment compared with greenhouse and field settings.

Another benefit to the location is the containment it gives the projects.

"When you look at all the potential liabilities that could arise from growing pharma crops in a field, it's obvious there's going to be a need to grow such crops in a contained manner," Ausenbaugh says. "While somebody argues about growing pharma crops outside, we can produce six or seven corn generations in a two-year period."

In addition to containment of high-value pharma crops, Ausenbaugh has had interest from seed companies as a way to accelerate early stage research.

Westin Rink, a Purdue agronomy graduate who manages the growing protocols and experiments for Ausenbaugh, is working on a hybrid experiment that has a photoperiod of 16 hours of light combined with 8 hours of darkness.

"Right now, we're comparing the effects of higher carbon dioxide levels on an experimental variety of drought-stressed corn. These rooms can control light, airflow, temperature, carbon dioxide, soil moisture and humidity," Rink says. "We've also grown tomatoes, tobacco and soybeans."

Next to the corncrib-sized building is an additional empty slab standing ready for the next growth chamber to be built. At less than 1,000 sq. ft., this prototype is a far cry from the hundreds of potential acres Ausenbaugh dreams of. There is room to grow.

"We have just two small growth chambers now, but we can have over 100 acres ready to go in six months," Ausenbaugh says. "Only about 45% of available space here has been finished out. So, there's room for expansion."

It's exciting; we're moving from a really cool idea to a service that should soon be of great value to many biotech companies," he says.

About the Cave

Ausenbaugh's company is a relatively small resident of the cavernous warehouse. The biggest tenant is Bridgestone/Firestone Tires, which stores thousands of tires in the cave. The consistent environment helps rubber last longer. Another tenant is the military, which stores a significant portion of its emergency ration MRE (Meals Ready to Eat) supply there. With more than 160' of limestone rock overhead, the place certainly seems secure.