1. Introduction
Vertical farms, warehouses, and shipping containers, collectively encompassing indoor agriculture (IA), provide the opportunity to produce year-round where growing seasons, land access, or food system infrastructure are limiting [
1,
2]. Set apart from greenhouses for its sole use of artificial lighting systems, IA facilities enable precise control of environmental conditions, improving produce quality and annual yields beyond that possible under field conditions [
3,
4]. In addition, these compact, closed systems offer more efficient use of resources such as land and water [
5,
6], contributing to a recent rising interest in producing leafy greens in IA [
2]. Lettuce (
Lactuca sativa) is particularly well-suited for IA production due to its compact growth, quick marketable biomass accumulation, and high market significance, enabling higher yield per area with efficient space utilization [
1].
Parameters influential to plant growth, such as radiation duration, quantity, and quality; day and night temperatures; airflow; relative humidity (RH); vapor pressure deficit (VPD); and carbon dioxide (CO
2) concentration can all be precisely manipulated in IA [
1,
2,
3,
4]. Mean daily temperature (MDT) and the photosynthetic photon flux density (
PPFD) strongly influence lettuce growth and development, as well as quality parameters such as flavor, color, nutrient content, and the occurrence of physiological disorders such as tipburn [
4].
The MDT influences plant developmental rate, including the rate of germination, rooting, leaf unfolding, and flowering; phytochemical biosynthesis and accumulation; and overall quality, with different crops having specific temperature ranges conducive for development [
7,
8,
9]. Overall plant growth, including shoot (branching, stem diameter, and leaf size) and root growth, foliage coloration, and flowering, is impacted by the daily light integral (DLI) and
PPFD [
10,
11].
Photosynthesis is driven predominately by the available
PPFD. Leaf photosynthetic rate increases linearly with
PPFD, followed by a quadratic slope until the light saturation point, at which a greater
PPFD does not further increase photosynthesis [
12,
13]. The ratio of plant productivity per
PPFD is the light-use efficiency—increasing the
PPFD above the light saturation point can reduce light-use efficiency as energy inputs increase without proportional yield responses. However, maintaining the
PPFD at or below the saturation point while extending the day length can allow for yield increases [
11,
14]. The light saturation point and DLI response are highly species-specific, can vary between cultivars, and depend on leaf area index and other environmental factors, such as temperature and CO
2 concentration [
12,
15].
The response of lettuce to
PPFD has been recorded in many studies [
11,
15,
16,
17,
18,
19]. Sago compared the growth of lettuce ‘Pansoma’ grown at 20 °C, 1200 μmol·mol
−1 CO
2, and under
PPFDs of 150, 200, 250, and 300 μmol∙m
−2∙s
−1 (DLIs of 13.0, 17.3, 21.6, and 25.9 mol∙m
−2∙d
−1) [
18]. Shoot fresh mass (SFM) and dry mass (SDM), relative growth rate, leaf number, and tipburn occurrence all increased with increasing
PPFD. SDM 35 d after sowing increased by 1.12-, 1.32-, and 1.42-fold under 200, 250, and 300 µmol∙m
−2∙s
−1, respectively, compared to lettuce grown under 150 µmol∙m
−2∙s
−1. However, there was no difference in SDM between plants under 250 and 300 µmol∙m
−2∙s
−1, indicating light saturation from 250 to 300 µmol∙m
−2∙s
−1 [
18]. Fu et al. grew romaine lettuce ‘Lvling’ under
PPFDs of 100, 200, 400, 600, and 800 µmol∙m
−2∙s
−1 (DLIs of 5, 10, 20, 30, and 40 mol∙m
−2∙d
−1) and a day/night temperature (14 h/10 h) of 20/16 °C (18.3 °C MDT) [
15]. Plants under
PPFDs of 200 to 600 µmol∙m
−2∙s
−1 had high light-use efficiency and yield, with 400 and 600 mol∙m
−2∙s
−1 producing the largest yields and 200 µmol∙m
−2∙s
−1 having the greatest light-use efficiency. Conversely, the lettuce had the lowest light-use efficiency and yields under 100 or 800 µmol∙m
−2∙s
−1. Signs of stress were present under 600 and 800 µmol∙m
−2∙s
−1, with the latter showing the highest level of stress as indicated by maximum photosystem II quantum yields (F
v/F
m) below 0.8. Due to high yield and relatively low-stress indicators, Fu et al. recommended maintaining a
PPFD of 400 to 600 µmol∙m
−2∙s
−1 for lettuce [
15].
Kelly et al. found that green butterhead lettuce ‘Rex’ and red oakleaf lettuce ‘Rouxaï RZ’ increased in SFM and SDM, leaf width and number, and chlorophyll concentration when DLIs increased from 6.9 to 15.6 mol∙m
−2∙d
−1 at an MDT of 22 °C, 60% relative humidity (RH), and 380 μmol·mol
−1 CO
2 [
11]. Additionally, the SFM under a DLI of 15.6 mol∙m
−2∙d
−1 was greatest under a
PPFD of 180 µmol∙m
−2∙s
−1 for 24 h∙d
−1 compared to the same DLI composed of
PPFDs of 216 and 270 µmol∙m
−2∙s
−1 with shorter photoperiods of 20 and 16 h∙d
−1, respectively. The SFM impact may be due to light-use efficiency decreasing under high
PPFDs, alongside light saturation points being reached, at which increasing photoperiod may increase yield while greater
PPFDs would not.
The influence of MDT on lettuce development, morphology, growth, and metabolism have been previously investigated [
4,
20,
21]. Ouyang et al. grew ‘Grand Rapids Tbr’ at 16, 18, and 20 °C under a continuous
PPFD of 210 µmol∙m
−2∙s
−1 for 30 days after transplant [
21]. Lettuce SFM and height was 38 and 18% (9.9 g and 1.9 cm) greater at 20 °C than at 16 °C, and SDM was 14% (0.5 g) greater at both 18 and 20 °C than at 16 °C.
The interaction of MDT and DLI on lettuce growth has also been investigated previously [
19,
21,
22]. For instance, Lee et al. grew crisphead lettuce cultivars ‘Adam’, ‘Manchu’, and ‘Sensation’ at day/night temperatures (12 h/12 h) of 22/18 °C (20 °C MDT) or 18/16 °C (17 °C MDT) and under
PPFDs of 150, 200, and 250 µmol∙m
−2∙s
−1 for the first 30 d after transplant (DAT) [
19]. From 30–60 DAT, the plants were grown at 18/16 °C (17 °C MDT) or 18/14 °C (16 °C MDT). For each cultivar, leaf number increased with temperature, while
PPFD only impacted ‘Manchu’ leaf number at the lower temperature when increased from 150 to 250 µmol∙m
−2∙s
−1, increasing from 22 to 27 leaves. Leaf biomass was lowest at the high MDT and 150 µmol∙m
−2∙s
−1 for all cultivars, with the greatest leaf biomass occurring at the high MDT and 250 µmol∙m
−2∙s
−1 for ‘Sensation’, low MDT, and 250 µmol∙m
−2∙s
−1 for ‘Adam’, and 250 µmol∙m
−2∙s
−1 at either MDT or 200 µmol∙m
−2∙s
−1 at the low MDT for ‘Manchu’. These findings exemplify that there are cultivar-specific responses to MDT and
PPFD.
The sustainability of IA spans several broad categories, including its environmental, social, and economic impact [
23]. In this study, the latter is estimated by identifying how revenues and key variable production costs are affected by changes in MDT and
PPFD in lettuce production. Temperature and lighting contribute directly to one of the largest variable production costs in IA production: energy costs [
24,
25,
26].
Given the strong influence of MDT and PPFD on lettuce growth, development, and quality, identifying conditions for improved resource efficiency and yield in IA is needed. Therefore, the objectives of this study were (1) to quantify if lettuce growth, development, quality, and yield are influenced by the interaction of MDT and PPFD; (2) to develop models that predict yield and economic viability under various PPFDs and MDTs. We postulated that (1) increasing PPFD will increase biomass production but increase the occurrence of tipburn; (2) higher temperatures will increase leaf number for both cultivars while reducing ‘Rouxaï RZ’ red pigmentation intensity and profitability.
2. Materials and Methods
Plant material and propagation conditions. On 28 April and 9 June 2020, seeds of red oakleaf lettuce ‘Rouxaï RZ’ and green butterhead lettuce ‘Rex’ (Rijk Zwaan; Salinas, CA, USA) were sown into 200-cell (2.5 cm × 2.5 cm) rockwool plugs (AO 25/40 Starter Plugs; Gordan, Milton, ON, Canada). The cultivars were selected due to their use in previous indoor production studies and commercial relevance. Plugs were presoaked in deionized water with a pH of 4.4 to 4.5 adjusted using diluted (1:31) 95 to 98% sulfuric acid (J.Y. Baker, Inc.; Phillipsburg, NJ, USA). The plug trays were covered with translucent plastic domes for 3 d to maintain high humidity during germination. Trays were placed in a walk-in growth chamber (Hotpack environmental room UWP 2614-3; SP Scientific, Warminster, PA, USA) with an MDT of 22 °C, CO2 concentration of 500 μmol·mol−1, and RH of 60%. Light-emitting diode (LED) fixtures (Ray66 Indoor PhysioSpec; Fluence Bioengineering, Austin, TX, USA) provided a total photon flux density (TPFD, 400–800 nm) of 180 µmol∙m−2∙s−1 and a light ratio (%) of 19:39:39:3 blue (400–500 nm): green (500–600 nm): red (600–700 nm): far-red (700–800 nm) radiation for 24 h. After 3 d, the photoperiod was reduced to 20 h until transplant at 11 d. Seedlings were sub-irrigated with deionized water supplemented with water-soluble fertilizer providing (in mg∙L−1): 125 N, 18 P, 138 K, 73 Ca, 47 Mg, 1.56 Fe, 0.52 Mn, 0.36 Zn, 0.21 B, 0.21 Cu, 35 S, and 0.01 Mo (12N–1.8P–13.3K RO Hydro FeED; JR Peters, Inc., Allentown, PA, USA). The pH and electrical conductivity (EC) were adjusted to 5.6 and 1.6 dS·m−1, respectively, as determined with a pH/EC probe (HI 991,301 pH/TDS/Temperature Monitor; Hanna Instruments, Smithfield, RI, USA). The pH was adjusted using potassium bicarbonate and sulfuric acid, while the EC was adjusted by adding deionized water and concentrated nutrient solution.
Hydroponic systems. On 9 May and 20 June 2020, 14 seedlings of each cultivar were transplanted 20-cm-apart into six 250 L, 0.9-m-wide by 1.8-m-long deep-flow hydroponic systems (Active Aqua premium high-rise flood table; Hydrofarm, Petaluma, CA, USA) distributed within three walk-in growth chambers described previously. Each hydroponic system contained a 4-cm-thick extruded polystyrene foam sheet to float on the nutrient solution. Plastic net baskets were placed into 4-cm-diameter holes in the polystyrene foam, and seedlings were placed in the baskets, so the rockwool was in contact with the nutrient solution. Deionized water supplemented with water-soluble fertilizer providing (in mg·L−1) 150 N, 22 P, 166 K, 87 Ca, 25 Mg, 1.9 Fe, 0.62 Mn, 0.44 Zn, 0.25 B, 0.25 Cu, and 0.01 Mo (12N–1.8P–13.3K RO Hydro FeED; JR Peters, Inc.), and 0.31 g·L−1 magnesium sulfate (Pennington Epsom salt; Madison, GA, USA). The EC and pH were adjusted daily to maintain an EC of 1.7 dS·m−1 and pH of 5.6, as described previously. Air pumps (Active Aqua 70 L·min−1 commercial air pump; Hydrofarm) connected to air stones (Active Aqua air stone round 10.2 cm × 2.5 cm; Hydrofarm) were used to increase the dissolved oxygen concentration.
Growth chamber environmental conditions. The air day/night (17 h/7 h) and MDT set points in each growth chamber were 22/15 (20 °C), 25/18 (23 °C), or 28/21 (26 °C), measured every 5 s by a resistance temperature detector (Platinum RTD RBBJL-GW05A-00-M 36B; SensorTec, Inc., Fort Wayne, IN, USA) and logged by a C6 controller (Environmental Growth Chambers, Chagrin Falls, OH, USA).
PPFDs of 150 or 300 μmol∙m
−2∙s
−1 were provided for 17 h∙d
−1 by LED fixtures (Ray66; Fluence Bioengineering), providing a DLI of 9.2 and 18.4 mol∙m
−2∙d
−1, respectively, averaged over several measurements (
Table 1). The LEDs were mounted ~130 and 95 cm above the crop canopy for the 150 and 300 μmol∙m
−2∙s
−1 treatments, respectively. Every 15 s, water temperature, leaf temperature, and
PPFD were measured using a thermistor (ST-100; Apogee Instruments, Logan, UT, USA), infrared thermocouple (OS36-01-T-80F; Omega Engineering, INC. Norwalk, CT, USA), and quantum sensor (LI-190R; LI-COR Biosciences, Lincoln, NE, USA), respectively, with means logged every hour by a CR-1000 datalogger (Campbell Scientific, Logan, UT, USA). A CO
2 concentration of 500 μmol·mol
−1 was maintained in each chamber with compressed CO
2 injection, measured with a CO
2 sensor (GM86P; Vaisala, Helsinki, Finland) and logged by a C6 Controller (Environmental Growth Chambers) every 5 s. Relative humidity was maintained at 58.5% (±4.6).
Growth data collection and analysis. Parameters assessed for lettuce quality included the foliage coloration of ‘Rouxaï RZ’, relative chlorophyll concentration (RCC), the maximum photosystem II quantum yields (F
v/F
m), and the dry mass. The foliage coloration of ten ‘Rouxaï RZ’ plants in each treatment was measured 35 d after sowing with a tristimulus colorimeter (Chroma Meter CR-400; Konica Minolta Sensing, Inc., Chiyoda, Tokyo), reported as International Commission on Illumination (CIE) L*a*b* color space values, which were then converted to hue angle (h°) and chroma (C*) as suggested by McGuire [
27]. The RCC of the most recent fully expanded leaf of ten plants of each cultivar in each treatment was then estimated with a SPAD meter (MC-100 Chlorophyll Meter; Apogee Instruments, Logan, UT, USA). One leaf of ten plants per treatment was then dark acclimated for >15 min using three of the manufacturer-supplied clips and then exposed to 3500 µmol·m
−2·s
−1 of red radiation (peak wavelength 650 nm) to saturate photosystem II and the fluorescence was measured, averaged, and reported as F
v/F
m by a portable chlorophyll fluorescence meter (Handy Plant Efficiency Analyzer; Hansatech Instruments Ltd., Norfolk, UK).
‘Rouxaï RZ’ and ‘Rex’ were harvested 36 and 37 d after sowing, respectively. SFM (g), length and width (cm) of the sixth fully expanded leaf, and leaf number (when >5 cm) were measured on ten plants of each cultivar per treatment. Plant height from the roots to the highest point of the foliage and the width at the widest point and perpendicular from the widest point was measured with a ruler and recorded. Incidence, but not severity, of tipburn was recorded. To provide an integrated measurement of plant size, the growth index (GI) was calculated (GI = {plant height + [(diameter 1 + diameter 2)/2]}/2) [
28]. The plant material was placed in a forced-air drier maintained at 75 °C for at least 3 d, weighed, and SDM was recorded.
An economic analysis was conducted using a simplified economic model developed to estimate the economic viability under various PPFDs and MDTs. This economic analysis integrates revenues and the most significant variable production costs in an IA farm [
25]. It is assumed that MDT and PPFD will affect plant growth and, therefore, yields and associated revenues, while electricity costs will be affected by changes in PPFD. Labor, consumables, and packaging costs are also tested for aggregated effects of variable production costs.
Space optimization: A base production model is firstly defined by setting aside a propagation area where lettuce grows up to transplant (SpcBT) and a production area where lettuce grows after transplant (SpcAT) according to a space ratio (SpcR), which is estimated as the ratio of the density before transplant (DenBT) to the density after transplant (DenAT). Given the relatively lower density after transplant, SpcAT is a multiple of a base area (B) and this space ratio. To estimate the minimum space required to grow these crops, this simulation establishes a minimum base area of 1 m
2 for propagation. The minimum size production module, or total farm size (TSpc), becomes the sum of a base area SpcBT and SpcAT. In this base production module, harvest occurs at the end of each cycle, which comprises a number of days before transplant (DBT) and days after transplant (DAT). However, a commercial farm requires continuous production for daily harvest. The criterion is met by using the length of cycle before and after transplant as multipliers to define the respective space required. Length of cycles, therefore, determines the number of growing modules operating sequentially. Total farm size producing daily harvest is thus estimated as:
Costs and revenues are applied to relevant areas. For broader applications, results are reported per area ($·m−2). Economic results are described from a cost minimization approach where the sum of variable production costs per area is represented as a proportion of revenues per area.
Electricity costs: The increased cost of electricity with greater PPFD were accounted for, but changes in heating or cooling costs to maintain each MDT were not accounted for, instead being kept constant. The model considers a 30% load in electricity costs in HVAC use; this may cause inaccuracies in situations where PPFD output influences temperature and required HVAC costs.
Specifically, electricity costs were estimated based on photoperiod (PhPer) and PPFD, applying an efficacy rate (ηPAR) of 2.5 and an electricity price rate of
$0.10 per kWh in all scenarios. DLI is estimated as a function of the photoperiod and PPFD used in each stage (
i), either before transplant (BT) or after transplant (AT). Daily energy cost (DEC) per m
2 takes the ratio of DLI to light efficacy (ηPAR) and multiplied by the electricity rate in kWh (CE):
Annual electricity costs (AnnEC) associated with lighting system and HVAC is assumed to be continuous throughout the year (y = 360 days on a financial year) and applied to the growing area respectively to the entire propagation and production areas, respectively to PPFD settings:
Labor costs: Labor costs were estimated as the number of hours spent per day per square meter in five general labor activities. The number of labor hours per square meter before transplant (L
BT) includes labor hours spent on seeding, while labor after transplant (L
AT) includes activities deemed to take place at the SpcAT area, including transplanting, harvesting, and packaging. It is assumed that cleaning (L
C) occurs daily in the entire farm area (TSpc). The estimation of the number of hours per activity takes two steps. It applies the ratio of one hour of labor dedicated to these five activities estimated by Kozai to the average labor hour per m
2 on a day [
25] on a small farm (equal to or smaller than 10,000 sq.ft. or 930 m
2). Labor hour per m
2 was estimated to be 0.038 of an hour, based on Agrilyst reported average total labor hours and average farm area [
29]. These estimates show seeding taking 11% of the daily labor time per m
2, transplanting and cleaning taking approximately 16% each, packaging 25%, and harvesting 32%. Total labor hours per day (L
D) for the entire growing area becomes:
Annual wages paid (AnnWg) is the product of daily labor in number of hours in one year by hourly wages (Wh), estimated to be on average
$12.46 per hour, and a 20% benefit loading (Wb):
Consumables costs: Seeds and growing media are the only two input costs considered in this analysis as these are one of the highest variable costs in production. These costs contribute to a better understanding of the distribution of these variable production costs, although not expected to affect results on a per m
2 basis. The cost of seeds (CSeed) is the average wholesale price for lettuce seeds, at
$0.03/seed. As for growing media (CMed), 1-inch rockwool hydroponic grow cubes starters were considered, at the cost of
$0.035 per unit, following average market prices. These are assumed to be single-seeded in the plant propagation stage and then transferred with the plant upon transplant into the production area. As such, along with seeds, these costs occur daily as a product of plant density before transplant (DenBT) per m
2 in each module of the propagation area (SpcBT). On an annual basis, the cost of inputs is estimated as follows:
Packaging costs are considered as well to evaluate whether more packaging material is required for increased yields. A unit price (CPck) of
$0.04 is considered, following average market prices, and applied directly to daily harvest (DH) weight which is converted into oz and divided by size of package (Sz) of 4.5 oz. Annual cost of packaging becomes:
Revenues: Daily harvest (DH) is estimated as a product of density per m
2, individual plant mass, and the size of each module of production area (SpcAT) being harvested daily. Annual revenue (AnnRev) becomes the product of daily harvest by the number of days in a financial year (y), converted from harvest in grams to pounds (lb.), and the retailer price (P) per pound adjusted by retailers’ margin (RetM). The latter adjustment provides the model with the flexibility to estimate the impact of market price changes. Changes in MDT and PPFD are not expected to affect crop loss and shrinkage, so these are set as 100% harvest sales and zero shrinkage in all scenarios.
Given the lack of formally reported market prices for premium lettuce at the time of this work, retail prices were obtained through an online search of groceries stores’ websites based in the U.S. Midwest (e.g., Wholefoods, Meijer, Kroger, Aldi), in Fall 2020. Market prices for selected leafy greens include products that were advertised as differentiated produce, ready for consumption, and sold in hard plastic packages. An average package size of 4.5 oz was adopted for the model simulation. Model simulations adopted the average price for single varieties at $13.41/lb. Wholesale prices were estimated using a standard industry gross margin of 50%, applied over the cost of goods sold (COGS).
The experiment was arranged in a split-block design with three temperature (three growth chambers) treatments as the main factor with two PPFD sub-factors, with 10 plants of each cultivar per treatment combination. The experiment was completed twice in time, and the growth chamber temperature treatments were randomized. Data were analyzed separately by cultivar with SAS (version 9.4; SAS Institute, Cary, NC, USA) mixed model procedure (PROC MIXED) for analysis of variance (ANOVA), tests of normality and homogeneity of variances were performed, and pairwise comparisons were performed with Tukey-Kramer difference test (p ≤ 0.05). SigmaPlot (version 14.5, Systat Software, Inc., San Jose, CA, USA) was used for regression analysis.
4. Discussion
Plant responses to temperature,
PPFD, and their interaction are species- and cultivar-specific. Therefore, the specificity of environmental responses, coupled with the tight profit margins of many vertical farm operations, emphasizes the need for crop modeling to predict yield and economic parameters. In the present study, SFM for ‘Rouxaï RZ’ and SDM for both cultivars were influenced by the interaction of MDT and
PPFD, while only the SFM of ‘Rex’ was influenced by
PPFD alone. Similar to other studies, the greatest SFM for both cultivars occurred under a relatively high
PPFD (~300 µmol·m
−2·s
−1) [
11,
18,
19,
30]. For instance, after 18 d at day/night temperatures (16 h/8 h) of 22/18 °C and 800 μmol·mol
−1 CO
2, SFM, and SDM of ‘Ziwei’ increased by approximately 30 and 60% as the
PPFD was raised from 150 to 300 µmol·m
−2·s
−1, respectively [
30]. Kelly et al. reported a 50 and 50% increase in the SFM and SDM of ‘Rex’ and 51 and 31% for ‘Rouxaï RZ’ under
PPFDs of 150 and 270 µmol∙m
−2∙s
−1, respectively, at an MDT of 22 °C, 60% RH, and 380 μmol·mol
−1 CO
2 [
11].
In the current study, we observed the greatest SFM for ‘Rouxaï RZ’ under a
PPFD of 300 µmol·m
−2·s
−1 and at MDTs of 23 and 26 °C (
Figure 1A). Similarly, Choi et al. reported that the SFM and relative growth rate of butterhead lettuce ‘Omega’ was greatest at 30/25 °C, compared to 20/15 °C, during the first 25 d, but by 35 d there was no difference in the SFM between plants at 20/15 and 30/25 °C, while the relative growth rate was lowest at 30/25 °C [
31]. This suggests that the impact of MDT on SFM may depend on the CO
2 concentration [
32], stage of growth, cultivar, plant density, and/or time to harvest.
In contrast, the lowest SFM in this study was under a
PPFD of 150 µmol·m
−2·s
−1 and MDT of 20 °C. Interestingly, the SFM of ‘Rouxaï RZ’ was similar between those harvested under a
PPFD of 300 µmol·m
−2·s
−1 and an MDT of 20 °C to those under 150 µmol·m
−2·s
−1 and MDTs of 23 and 26 °C. This indicates that a greater
PPFD does not always increase yield or crop quality with a suboptimal MDT. This aligns with the findings of Lee et al. [
19], where the SFM of ‘Sensation’ was lower under a
PPFD of 250 µmol·m
−2·s
−1 and MDT of 17 °C than under a
PPFD of 200 µmol·m
−2·s
−1 and MDT of 20 °C. However, in contrast to our results where the SFM of ‘Rouxaï RZ’ was greater at 23 and 26 °C than at 20 °C under a
PPFD 150 µmol·m
−2·s
−1, they reported that SFM under 150 µmol·m
−2·s
−1 was greater at 17 °C than at 20 °C. This may be due to cultivar and other environmental and cultural differences, such as the vapor-pressure deficit (VPD) or CO
2 concentration, both of which can influence the photosynthetic rate.
Morphological changes in response to MDT and
PPFD were observed for both cultivars. As the
PPFD increased from 150 to 300 µmol·m
−2·s
−1, leaf width for both cultivars increased; however, the GI and leaf length of ‘Rex’ decreased at the higher
PPFD (
Table 2). The compact growth of ‘Rex’ and greater leaf width of both cultivars under higher
PPFDs align with the findings of Kelly et al. [
11]. Greater leaf area and stem lengths, alongside reduced leaf thickness, have been observed in many species in response to reduced
PPFDs, including lettuce [
16,
22,
33,
34]. An increase in leaf area, coupled with a reduction in leaf thickness, can improve light interception without increased assimilate demand [
22,
34].
The increase in leaf number in response to MDT is consistent with the understanding that developmental rates are primarily dependent on temperature [
9]. Interestingly, the leaf unfolding rate only increased from an MDT of 20 to 23 °C, not 23 to 26 °C. This may be indicative of an optimum temperature (T
opt) being reached between 23 and 26 °C, given that the rate of development is often characterized by a linear increase from the base temperature (T
b) to the T
opt, after which developmental rate plateaus or declines to the maximum temperature (T
max) [
35]. The T
b, T
opt, and T
max vary by cultivar and are influenced by other environmental conditions, including the DLI [
34,
35].
In the current study, we determined that
PPFD only influenced leaf number for ‘Rouxaï RZ’, and to a lesser extent than MDT. This is consistent with the findings by Kelly et al. [
11], where leaf number increased by 13% as
PPFD increased from 150 to 270 µmol·m
−2·s
−1 under a 16-h photoperiod. Findings by Sago suggest that the influence of
PPFD on leaf number may be dependent on the duration of the harvest cycle [
18]. Leaf number in ‘Pansoma’ butterhead lettuce grown at 20 °C increased as
PPFD increased from 150 to 300 µmol∙m
−2∙s
−1 when harvested 30 DAT; however, at 35 DAT, leaf number only increased under
PPFDs of 150 or 200 µmol∙m
−2∙s
−1. Additionally, there appear to be cultivar-specific responses for leaf number in lettuce [
11,
19]. When comparing crisphead lettuce cultivars ‘Adam’, ‘Manchu’, and ‘Sensation’, leaf number was dependent on MDT and cultivar, while only ‘Manchu’ was impacted by
PPFD interacting with MDT [
19].
In our study, tipburn incidence in both cultivars was only influenced by
PPFD, with ‘Rex’ having a greater incidence than ‘Rouxaï RZ’ (
Table 2). The cultivar difference may be attributed to morphological differences; ‘Rex’ forms compact heads that decrease transpiration at the growing point, while ‘Rouxaï RZ’ does not produce a head. The influence of
PPFD on tipburn has been described in several studies [
18,
36]. Sago reported that the number of leaves exhibiting tipburn increased with
PPFD from 150 to 300 µmol∙m
−2∙s
−1, concluding tipburn development is proportional to fresh and dry weight, relative growth rate, and leaf number [
18]. Additionally, the total calcium concentration of lettuce increased with
PPFD from 150 to 300 µmol∙m
−2∙s
−1; however, the concentration of calcium within the inner leaves remained similar regardless of the
PPFD [
18].
We did not find a relationship between tipburn incidence and MDT. Similarly, Lee et al. reported that tipburn occurrence in ‘Dambaesangchuesse’ and ‘Mostcheongssam’ was similar at MDTs of 18, 22, and 25 °C and under a
PPFD of 200 µmol∙m
−2∙s
−1 from day 30–40 after sowing [
37]. Conversely, Lee et al. reported that the increased growth rate of crisphead lettuce ‘Adam’, ‘Manchu’, and ‘Sensation’ at MDTs of 18.5 °C brought higher incidence of tipburn when compared to those grown at 16.5 °C [
19], similar to the incidence in lettuce ‘Batavia Othilie’ at higher MDT observed by Carotti et al. [
22]. A greater VPD can increase transpiration rates, potentially reducing tipburn occurrence [
4,
37]. In our study, maintaining a ~60% RH at each MDT calculated into VPDs of ~0.9, 1.1, and 1.3 kPa at 20, 23, and 26 °C, respectively. The greater VPDs at 23 and 26 °C may have reduced tipburn incidence due to greater transpiration compared to the lower VPD at 20 °C, mitigating MDT-influenced tipburn. Additionally, there may have been impacts on tipburn severity by MDT or
PPFD, but the severity was not recorded in our study.
The marketability of certain crops is influenced by their unique coloration, so a balance between optimal temperature for yield and optimal temperature for coloration must be considered [
38]. MDT and
PPFD affect anthocyanin biosynthesis and accumulation of Compact growth of ‘Rex’ [
7,
39]. In our study, h° and L* of ‘Rouxaï RZ’ foliage was influenced by the
PPFD, while C* was influenced by the MDT and
PPFD interaction (
Table 2;
Figure 1G). Increasing
PPFD from 150 to 300 µmol·m
−2·s
−1 reduced the h° from 110.7 to 84.4°. On the color wheel, a h° of 0°/360° indicates red, 90° indicates yellow, and 120° indicates green; therefore, increasing the
PPFD caused foliage to move toward yellow and red values, away from green and blue values. The L*, a scale of lightness (high values) and darkness (low values), decreased from 38.7 to 29.8 under 150 and 300 µmol·m
−2·s
−1, indicating darker foliage at a higher
PPFD. Increasing the
PPFD from 150 to 300 µmol·m
−2·s
−1 caused a lower C* regardless of MDT, indicating that the foliage became less colorful and closer to gray. However, at a
PPFD of 150 µmol·m
−2·s
−1, the C* was influenced by the MDT, increasing from 17.7 to 27.3 as MDT increased from 20 to 26 °C. Overall, this indicates that foliage was a darker yellow and red at lower MDTs and high
PPFD, while high MDT and low
PPFD had vibrant, light-green foliage.
The economic analysis focused on the variable production costs per area as a percentage of revenue per area. A higher MDT improved the economic results across treatments, while a greater
PPFD only improved the economic results for ‘Rouxaï RZ’. Increasing the
PPFD up to 300 µmol·m
−2·s
−1 improved overall revenue across cultivars and temperatures, but this was not proportional to the doubling of electricity cost and packaging costs for ‘Rex’. Our model was unable to account for the changes in the costs of heating and cooling. The cost of climate control in plant factories varies by location, seasonality, and climate control equipment. Typically, estimated cooling costs are greater in plant factories than in greenhouses, with components such as light fixtures releasing heat [
26,
40]. Additionally, our economic analysis did not account for the impact on crop quality and marketability, such as foliage coloration and tipburn incidence. Focusing on the economic effect of alternative MDT and PPFD on lettuce growth, the economic analysis considered revenue and costs associated with yield applying constant prices and zero harvest loss and shrinkage costs. However, ‘Rex’ had the greatest tipburn occurrence under a
PPFD of 300 µmol·m
−2·s
−1, which was deemed to have worse economic results than at 150 µmol·m
−2·s
−1 without accounting for product loss from tipburn. Further research is also needed to identify the effect of premium prices paid and specific niche markets for morphological changes such as foliage coloration and leaf texture on revenues.