3D-printed soil? U of T startup expands sustainable urban farming footprint in Toronto

A startup co-founded by a University of Toronto graduate student has its roots in an experience that is all too common for many of us.

He kept forgetting to water his plants. 

“I was working in a plant immunity biology lab, so if I didn’t water them, I’d have no plants to do experiments with,” says Adnan Sharif, who is pursuing a master’s degree in the department of chemical engineering and applied chemistry in the Faculty of Applied Science & Engineering.

He says his solution was inspired by his father.

“My dad is a mechanical engineering professor at a university in Japan, and he knows a lot about manufacturing materials with porous, three-dimensional structures,” he says. “That’s how I got the idea to make my own 3D-printed soil construct, which could retain water for a week or more.

“That way, I wouldn’t have to go into the lab and water the plants so often.” 

The innovation – which Sharif came up as an undergraduate working in the lab of Keiko Yoshioka, a professor in the department of cell and systems biology in U of T’s Faculty of Arts & Science – is one of several that now underpins Lyrata, a startup that grows fresh produce for caterers and high-end restaurants across the Greater Toronto Area. 

The company, which got its start in a greenhouse on U of T’s St. George campus, has recently expanded with operations at U of T Scarborough and Casa Loma, a museum, event space and historic site in midtown Toronto.

Growing plants without soil, known as hydroponics, is a technique commonly used in greenhouses worldwide. But Sharif and his team see an opportunity to make the industry more sustainable, starting with the soil replacement that the plants grow in.  

“The product that almost everyone uses today is basically the same as house insulation,” Sharif says. “It’s made from rocks that are mined in remote places and shipped hundreds of kilometres to a production facility, where they are heated to thousands of degrees in a giant furnace to make a porous, chemically inert material. This material then needs to be shipped again to where it’s needed, and when you’re finished, you throw it in the garbage.” 

By contrast, Lyrata’s SmartSoil is 3D-printed using biopolymers such as polylactic acid, which is derived from corn. These materials can be locally sourced and require much lower temperatures to melt and form into porous structures. 

When the growing cycle is complete, the product goes through a low-heat proprietary cleaning process and can be used again. Sharif says that SmartSoil has a total lifespan of about two years, after which it can be composted along with crop residue. Together, these changes greatly lower the carbon footprint of indoor farming. 

In 2020, Sharif and his co-founders brought his idea to The Entrepreneurship Hatchery, U of T Engineering’s startup incubator and one of several entrepreneurship hubs across U of T’s three campuses. Through the Hatchery’s Nest process, they were connected with business mentors, including alumnus Xavier Tang, a consultant and venture capitalist who still advises the company today.

Over the next few years, the team evolved, with some original members leaving and others joining. They include Leo Hua, who has been pivotal to speeding the development of 3D printable soil. The concept evolved, too, as the team realized that producing food was a better business for Lyrata than rather than selling their growth medium to other farmers. 

The Hatchery team – in particular, Executive Director Joseph Orozco, Go-To-Market Lead Erika J. Murray and a team of work-study students, mentors and legal externs – helped Lyrata develop their technology and business. In 2022, the Hatchery provided $155,000 in seed funding, enabling the founders to be employed by their company and further supporting business development. The funding also enabled the company to rent greenhouse space on campus, where they began growing lettuce to provide to Spaces and Experiences at U of T.

Lyrata also developed something new: a modular unit that works exclusively with their SmartSoil and contains everything required to produce a variety of indoor crops – from lights and growth medium to irrigation systems.

“None of these technological and business developments would have taken place without the generous support of the over 50 Hatchery mentors, work-study students, and legal externs who contributed to our success,” says Sharif.

“Our current concept is what we call farming-as-a-service,” Hua adds.  “The SmartGrow unit we developed is small enough to fit into a standard parking spot. Our clients sign a contract with us to place a unit on their site and we take care of everything from planting to harvesting.  

“For a flat fee, they get a self-contained farm that provides a reliable quantity of their desired crop over a set period of time.” 

In addition to providing a locally sourced, sustainable product, Sharif says the approach can also help mitigate fluctuations in the price of wholesale produce. 

“In Canada, most of our lettuce comes from California, which has been dealing with drought and many other issues,” says Sharif. “Supply chain disruptions due to COVID-19 were also a big challenge for restaurants, which have very thin margins to begin with. At one point, the price of lettuce increased by a factor of six, so you can imagine the effect that would have.” 

So far, Lyrata has produced more than 15 different types of crops, including basil, parsley and mizuna, also known as Japanese mustard greens. 

Support from the U of T Engineering community has been key to Lyrata’s success.

For example, it was a U of T Engineering alumni connection that recently led to Lyrata launching an installation at the historic Casa Loma museum and landmark in Toronto. 

“Lyrata’s competitive edge is that they provide an on-site, full service and they do not take up very much space,” says Nikol Watlikiewicz, Casa Loma’s horticulture and grounds manager. “In a small corner of our potting shed, we were able to build two grow units that provide a good yield weekly, without having to train our staff on the complicated system. 

“Growing indoors gives us the stability and control that traditional agriculture does not. It’s an excellent example of how engineers can help solve the global food crisis with innovative thinking.” 

In August, Lyrata launched another growing unit at U of T Scarborough, located within the Harmony Commons Dining Hall.

The priority for the next few years is growing Lyrata’s crop offerings and client base with ongoing support from The Hatchery. The incubator has facilitated graduate student placements through Mitacs, with matching funds. It also backed a recent $167,500 project with the Ontario and Canadian governments through the Sustainable Canadian Agricultural Partnership program to further advance the yield and efficiency of the SmartSoil system.

“The fact we’ve been able to come this far in such a short time is in large part due to the help we’ve had from U of T Engineering, and especially the Entrepreneurship Hatchery,” says Sharif. 

“Whether it was getting seed funding, finding mentors, hiring work-study students or making important connections through their alumni network, we wouldn’t be here without their support.”