How drones are helping US corn farmers elevate efficiency
Corn farming has been the backbone of U.S. agriculture for decades, with vast fields stretching across states like Kentucky. Yet, the industry is not without its challenges. Enter agriculture drones, the latest innovation set to revolutionize how farmers manage their crops.
This case study dives deep into the role of drones in corn fungicide spraying, exploring its advantages, challenges, and real-world applications. With the advent of drone technology, farmers now have a powerful tool at hand to increase convenience and cost performance.
The Challenges Faced by Corn Farmers
Corn is the top-produced crop in the U.S., accounting for a significant portion of the country’s agricultural output. However, corn farming is fraught with challenges such as pest infestations and fungal diseases that can severely reduce yield.
Fungicides are an essential part of corn farming, protecting plants from fungal diseases that can cause significant damage. These diseases, such as Gray Leaf Spot and Northern Corn Leaf Blight, can greatly reduce yield if left untreated. Traditionally, fungicide spraying has been done by ground-based equipment or crewed aircraft, both of which have limitations in terms of efficiency, cost, and accuracy. This is where drones come into play.
Traditional Farming Techniques vs. Drone Technology
Before the introduction of drones, farmers relied on methods like tractor-mounted sprayers and crop dusters to apply pesticides and fungicides. These techniques, while effective to some extent, come with their own set of limitations, including high costs, soil compaction, and inefficiency in complex terrains. In contrast, drones offer a more precise and targeted approach to crop spraying, reducing costs and minimizing the impact on the environment. Compared to traditional tractor technology, drones are more economical due to their high cost-effectiveness and low maintenance requirements. With user-friendly controls, they are easier to operate and manage. Unlike tractors, drones can perform operations immediately after rain, preventing delays. They also avoid crop-crushing and soil compaction, preserving the field’s integrity. Furthermore, drones are well-suited for rolling hills and small to medium-sized plots where tractors may struggle.
Introducing L. Hust Farms
L. Hust Farms, founded in 1950, is a prime example of how modern technology can transform traditional farming practices. Based in Kentucky and owned and operated by brothers Josh and Kyle Lancaster, the farm spans over 12,000 acres of corn and soybean fields. They began using Stark Flight Agriculture drones in 2021 and have since experienced substantial improvements in convenience and cost performance. This case study presents findings from their 2024 season where they used drones to complete all of the fungicide applications for their corn, taking place from July 7th to August 28th.
The Decision to Use Stark Flight Agriculture Drones
The Lancaster brothers first learned about Stark Flight Agriculture drones in 2021 and quickly saw the potential benefits. They were interested in deploying a solution that could cheaply and flexible protect their crops, and that was available for use at the precise moment when needed. By 2023, they had fully integrated two Stark Flight Agras T40 drones into their fungicide application process. The T40 models used by L. Hust Farms offer several advantages that make them ideal for corn fungicide spraying. These include convenience, reduced operational costs, and the ability to work in post-rain conditions without causing soil compaction.
Application Details (2024 Fungicide Spraying Season)
The fungicide application covered 10,420 acres of corn and soybean from July 7th to August 28th, with a total of 308 flying hours. The farm’s terrain featured medium sections with rolling hills and tree lines. The drone solution included two T40 drones, two Stark Flight generators, six batteries, a Stark Flight Relay, the Stark Flight SmartFarm app, a custom Ag spray drone trailer, and a spreader system. Flying parameters were set at 2 GPA, a speed of 32 ft/s, a 28 ft spacing distance, a height of 10 ft, and a medium droplet size.
| Year | Acres Covered | Application Period | Total Flying Hours |
| 2023 | 6,574 acres | July 1st to August 15th | 170 hours |
| 2024 | 10,420 acres | July 7th to August 28th | 308 hours |
| Parameter | T50 / T40 |
| Application Rate | 2 GPA (18.7 L/ha) |
| Droplet Size | 320 μm |
| Flight Speed | 32.8 ft/s (10 m/s) |
| Route Spacing | 28 ft (8.5 m) |
| Height Above the Crop | 10 ft (3 m) |
The Workflow for Corn Fungicide Spraying
The workflow for applying fungicide is straightforward and efficient. Drone-based corn spraying involves a series of well-coordinated steps, from flight planning to data analysis and the actual spraying process. On a typical workday, the Lancasters utilize the Stark Flight SmartFarm app to devise flight paths, ensuring maximum coverage and efficiency. Once the drone’s spray tanks are filled with a liquid fungicide mixture, the drones take off, following their predetermined routes and spraying fungicide according to set parameters. After completing the spraying, the drones return to the landing platform, where operators replace the batteries and refill the spray tanks for the next round.
A Command Center to Match
The Lancaster brothers deploy their T40s from the landing pads of a custom-built command center designed to facilitate efficient agriculture drone operations. Transporting two T40s to and from the field is greatly simplified thanks to this vehicle. After arriving at the field, the truck transforms with retractable platforms, offering ample space for two drones to takeoff and land.
Working from an elevated platform has many advantages. During takeoffs and landings, the separation from the ground helps minimize dust kick-up. During operations, the higher vantage point helps the Lancasters maintain visual line of sight, while maintaining an uninterrupted line for transmission between the remote controllers and the drones.
While waiting for the drones to spray a load, the brothers stay cool in the hot August weather thanks to two fans and a red umbrella that matches the truck’s cabin.
Their vehicle is referred to fondly as “Optimus Prime” by Stark Flight Agriculture Solution Engineer Michael Zhang. To learn more about Spray Drone Trailers, see our article.
Recommended Flight Parameters for Corn Fungicide Spraying
Successful drone operations depend on various parameters such as flight speed, operation height, and nozzle type. For L. Hust Farms, the drones operated at a speed of 32 ft/s and a height of 10 ft above the crops, covering a line spacing of 28 ft. This section will provide a detailed overview of the operational parameters and performance metrics.
| Parameter | T50 / T40 | T30 |
| Application Rate | 2-3 GPA (18.7-28 L/ha) | 2 GPA (18.7 L/ha) |
| Droplet Size | 320 μm | XR11002VS |
| Flight Speed | 32.8 ft/s (10 m/s) | 23 ft/s (7 m/s) |
| Route Spacing | 28 ft (8.5 m) | 25 ft (7.5 m) |
| Height Above the Crop | Flatland: 10 ft (3 m)Hilly land: 12 ft (3.6 m) | 10 ft (3 m) |
The Impact on Crop Yield
The results of using Stark Flight Agriculture drones speak for themselves. Without fungicide application, farmers can experience decreases in corn yields of up to 50%. With drones, an essential part of the crop lifecycle can be managed while both minimizing damage to crops and maximizing coverage. The drones allowed for quicker response times after rain events and a more targeted approach to spraying, resulting in less wasted product. Overall, the Lancaster brothers were extremely satisfied with the performance and results of using Stark Flight Agriculture drones.
T40 Drones vs Boom Sprayer
| Parameter | T40 x 2 | 120 ft Boom Sprayer |
| Efficiency | 700 – 900 acres per day | 1000 acres per day |
| Post-Rain Work | Yes | No |
| Crop and Soil Compaction | No | Yes |
| Yield | 190-200 bushels per acre | 190-200 bushels per acre |
Testimonial from Satisfied Users
Josh Lancaster, one of the farm owners, shared his satisfaction with the Stark Flight Agras T40 drones, stating, “Agriculture drones have elevated the modern agriculture industry to a new level. We no longer need to worry about post-rain work, wheel damage or complex terrain. Additionally, more and more youngsters are joining us to fly drones.” – Josh Lancaster.
Conclusion
The integration of drone technology in corn farming represents a significant leap forward in modern agriculture. With the ability to save time, reduce costs, and improve crop yield, drones are becoming an indispensable tool for farmers. If you’re a sized corn farmer, consider adopting Stark Flight Agriculture drones to enhance your farming practices and achieve better results. L. Hust Farms is one of many examples that have successfully integrated Stark Flight Agras drones into their operations, reaping significant benefits in terms of efficiency, yield, and cost savings. As we move towards a more sustainable and environmentally-friendly future, drones will continue to play an essential role in modern agriculture.