Cannabis Consulting Case Study
HEXO Corp | Ontario, Canada
Catalyst BC’s engagement with HEXO transformed one of North America’s largest cannabis greenhouses into a more disciplined, data-driven, and profitable operation. Learn how it was achieved with the guidance of Catalyst BC Cannabis Consultants.
A Decade of Harvest Success—Trusted by Leading Cannabis Operators Worldwide
Overview: Why HEXO Corp Needed Cannabis Consulting Support
HEXO Corp operated one of the largest cannabis greenhouses in North America, a 1.3 million sq ft facility with complex environmental systems, variable crop zones, and hundreds of employees spanning multiple shifts. Despite its impressive scale and infrastructure, the site faced inconsistent yields, workflow and environmental control inefficiencies, and widespread staff disengagement driven by unclear accountability and constant procedural changes.
The company needed to restore operational consistency, elevate performance, and rebuild a culture of execution and accountability. Catalyst BC was brought in to stabilize the system, empower the workforce, and drive sustainable productivity gains through a data-driven, hands-on approach.
Business Profile:
- Location: Masson & Leamington, Ontario, Canada
- Facility Size: 1.3 million sq ft greenhouse campus
- Employees: 800+
- Sector: Cannabis Cultivation & Processing
- Engagement Focus: Operational Optimization, Yield Improvement, and Organizational Performance
Why HEXO Corp Chose Catalyst BC as Their Cannabis Consultants
HEXO Corp selected Catalyst BC as their cannabis consulting partner to address critical operational challenges that were limiting consistency, efficiency, and growth. The company was experiencing inconsistent yields driven by uneven environmental conditions and variable performance across greenhouse zones, resulting in fluctuating product quality.
Operational inefficiencies further compounded the issue, with irrigation inconsistencies, workflow gaps, and imbalanced climate controls slowing down productivity. These hurdles were intensified by cultural resistance within the organization, as employees struggled with fatigue from frequent changes, unclear operating procedures, and a lack of structured technical training. Additionally, communication breakdowns between leadership and operational teams created misalignment around priorities and expectations.
Catalyst BC was chosen for their proven ability to diagnose these complex challenges and implement practical, data-driven solutions that align teams, enhance processes, and restore consistent performance.
Key Areas of Focus:
- Inconsistent Yields: Uneven quality and production across greenhouse zones.
- Operational Inefficiencies: Irrigation uniformity, workflow coordination, and environmental balance.
- Cultural Resistance: Employee fatigue from shifting directives, lack of clarity, and consistent technical training.
- Leadership Disconnect: Breakdowns in communication between management and operations teams.
Catalyst BC’s Strategic Approach
Catalyst BC deployed an integrated operational improvement program that combined rigorous data analysis, on-site coaching, and organizational alignment to deliver sustainable results across every business level.
Comprehensive Operational Audit & Benchmarking
Catalyst BC conducted a complete assessment of HEXO’s greenhouse operations, benchmarking each zone for yield, throughput, and environmental stability. Key performance indicators were defined, visualized, and tracked daily to create transparency and accountability at every level of the organization.
End-to-End Optimization Strategy
Leveraging expertise across genetics, irrigation, and environmental controls, Catalyst BC identified bottlenecks and implemented corrective actions. By aligning environmental conditions with plant physiology and rewriting SOPs for precision and repeatability, Catalyst achieved a 25-35% increase in yield consistency over multiple crop cycles across the entire flowering canopy.
Onsite Coaching & Staff Empowerment
Catalyst BC embedded cultivation and operations specialists within the HEXO team to mentor supervisors and technicians. Through daily Gemba-style walkthroughs and real-time problem solving, staff gained ownership of their roles and confidence in the process. Employee engagement and retention improved as a direct result of this hands-on mentorship model.
Executive Alignment & Change Management
Catalyst facilitated weekly leadership sessions to close the gap between executive priorities and production execution. Unified communication channels and shared KPIs enabled faster decisions and greater cross-departmental cohesion.
Leveraging Global Network & Technical Expertise
Drawing on its experience in construction and network of suppliers and engineering partners, Catalyst BC helped resolve facility issues in lighting, HVAC, and irrigation systems quickly and cost-effectively, accelerating problem resolution and improving operational continuity.
Key Improvements in Cannabis Cultivation and Operations
Within months, HEXO Corp achieved substantial and sustained gains in both production and culture:
- Yield Increase: 25-35% improvement in average output across key zones.
- Consistency: 20% reduction in harvest-to-harvest variance.
- Efficiency: Improved irrigation uniformity and environmental control reduced crop loss and input waste.
- Engagement: Staff retention and morale improved through clear direction and visible progress.
- Leadership Effectiveness: Stronger alignment between management and operations enabled faster strategic execution.
“Catalyst BC helped HEXO devise comprehensive and pragmatic operational improvement plans and supported change management through the organization. Their deep understanding of greenhouse operations brought measurable and sustainable improvements, from lighting and irrigation systems to organizational dynamics.”
– Taras Korec, P. Eng., P. Log., Senior Vice President, Procurement and Logistics, HEXO Corp.
Key Lessons from Large-Scale Cannabis Greenhouse Optimization
- Embedding experienced partners with hands-on knowledge of greenhouse operations, horticultural science, and cannabis specific crop steering is critical to execution.
- Aligning executive vision with operational KPIs creates a shared language and direction for performance.
- Data-driven decisions, alerts, and daily visibility build trust and accountability throughout the organization.
- When reinforced with discipline and coaching, pragmatic, incremental improvements compound into significant performance gains.
About Catalyst BC – Cannabis Business Consulting Experts
Catalyst BC’s engagement with HEXO transformed one of North America’s largest cannabis greenhouses into a more disciplined, data-driven, and profitable operation. By combining technical precision with human empowerment, Catalyst BC helped the organization achieve sustainable performance gains and restore confidence across its entire operation.
Frequently Asked Questions:
HEXO Cannabis Consulting Project
What challenges did HEXO face before partnering with Catalyst BC?
HEXO struggled with inconsistent yields, environmental control inefficiencies, and workforce disengagement due to unclear processes and frequent operational changes. Catalyst BC was brought in to stabilize systems and improve productivity across its large-scale greenhouse operations.
How did Catalyst BC help improve HEXO’s cannabis yields?
Catalyst BC implemented a data-driven cultivation optimization strategy that aligned environmental conditions, genetics, and SOPs. This approach improved yield consistency by 25–35% across multiple greenhouse zones.
What specific operational improvements were made at the HEXO facility?
Catalyst BC optimized irrigation uniformity, environmental control systems, and workflow coordination. The consulting team also improved communication between leadership and staff to increase accountability and alignment.
How large is the HEXO greenhouse featured in this case study?
HEXO operated a 1.3 million square-foot cannabis cultivation and processing facility in Ontario, Canada—one of the largest in North America.
What measurable results were achieved through Catalyst BC’s engagement?
The project resulted in a 25–35% yield increase, a 20% reduction in harvest variance, improved environmental consistency, and stronger employee engagement across the organization.
How did Catalyst BC address cultural resistance within the HEXO team?
Catalyst BC embedded consultants on-site to coach supervisors and technicians directly. This hands-on mentorship model helped rebuild trust, improve morale, and create a culture of ownership and continuous improvement.
Why was Catalyst BC chosen as HEXO’s cannabis consulting partner?
HEXO selected Catalyst BC for their proven track record in cannabis operational optimization, facility performance improvement, and leadership alignment within large-scale cultivation environments.
What services from Catalyst BC were used during the HEXO project?
Catalyst BC provided operational optimization, cultivation advisory, controlled environment strategy, staff training, and change management support to deliver lasting performance improvements.
How does Catalyst BC approach greenhouse optimization projects?
Catalyst BC uses a combination of technical analysis, data benchmarking, and hands-on coaching to identify inefficiencies, improve environmental systems, and strengthen organizational processes for sustained growth.
How can other cannabis operators benefit from Catalyst BC’s expertise?
Cannabis operators seeking to improve yield consistency, operational efficiency, or workforce performance can engage Catalyst BC for customized consulting support tailored to their specific facility and business goals.
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