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If you want to support 40 lights of bloom (4 plants per light or 80 plants per room)), and you have to veg in 5 gallon containers (16 per light), then it seems like you would need 20 lights in your veg room, if you're looking at a 30 day cycle. This way you could minimize on transplanting labor and harvest 20 lights per month with 80 plants per room. Always vegging 160 plants in the veg room.
If you only have the 10-10-20 light rooms, 3 rooms total. You could simply veg in the 10 light room.
The best answer to this question depends on how much transplanting your willing to do. The more veg lights, the less labor.
Does that make sense?
"How to I organize the Veg room so that I can transfer the plants in Veg directly into the flower rooms like I would w/ rock wool? Do I have to Veg teens in 5 gallon buckets under MH lights? Suggested square footage for Veg and # of lights?"
In that first sentence above, "like rockwood" I imagined that you wanted to directly roll some plants over into a flower room without having to transplant...like if you had 4x4 cubes on 6 inch slabs...if you're vegging on slabs from the start, then you obviously have to have a huge veg room with tons of wasted light.
Sorry for the confusion, so the answer is NO, you do not need to veg in 5 gallons and you can totally veg in 4x4 cubes. That is what I do. I use 4x4 ebb and flow tables with a 40 gallon res underneath each table. But I think if you're doing a DWC system, you want really large plants. In my opinion, a 4x4 cube doesn't have enough root space to support a huge top heavy plant. Maybe you could try 6 or 8 inch cubes?
I veg in 4x4 cubes, but only for 3-4 weeks max and by that time, they area kind of maxing out the cube. Then we transplant into a 2 gallon hydroton ebb and gro bucket. I flower with 9 plants per light, so my plants are smaller than yours.
So I guess we need to know how many flowering lights is your goal? We have to know what size panel you have and your budget...or we're simply wasting time.
What is the reason you choose the number 40?
One of my warehouses is a 40 light setup, but I choose 40 lights because I had 300 amps of power and wanted a 1 month cycle with veg room and dry room. Don't forget to incorporate a dry room into your design. You can easily cool the space with a zone off of one of your AC's and it'll increase your annual numbers by a new trucks worth.
I have room for 40 lights in Flower + a 15 x 14 veg room. It would be 2- 10 light rooms and 1- 20 light room.
Or, I can do 3 - 10 light Flower rooms (30 lights total Flower) and a 30 x 14 Veg room. The size of the rooms is simply dictated by what already exists and walls that can be easily built.
Layout either way has 2 buckets per 1000 watt HPS in Flower, so it's 20 5gal buckets per flower room.
Power is 200 AMP. I'm thinking 3-10 light flower rooms and a big veg room is a better option so I can Veg in 5 gallon buckets. That way I can fit 80+ 5gal buckets in veg to really establish my plants before they enter flower - no to mention to ability to really pick the winners and eliminate all the runts before Flowering.
Trim, Dry, Storage, etc is all covered, no worries there.
I noticed that you said 200 amps? Is your main panel 200 amps?
40 1000's x 5 amps= 200....
What about AC, and everything else?
You will need to upgrade your service to 400A, or use Bobby's advice.
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