Designing your Greenhouse for Efficiency
- 2. This talk will be on my blog.. www.michael-kilpatrick.com
- 3. Background • Ran Kilpatrick Family Farm 2004-2015 • Have interned at Polyface, Inc, Pleasant Valley Farm, collaborated with Eliot Coleman, others. • Now consult full-time for clients/companies from Alaska to New York • Work with Four Season Tools as an Agricultural Specialist.
- 4. Passionate about… • Helping small farms become sustainable and effective businesses • Four season farming and season extension • Slow Tools and machinery outfitting for small farms
- 5. We were in Middle Granville, NY - an hour north of Albany, NY Zone 4b
- 7. 12-15 acres in vegetables
- 8. 25-30 Acres in Cover Crop
- 9. 8 full time employees
- 11. 1/3rd acre of Tunnels
- 13. 3,000 yards of compost annually
- 22. 4 Summer Markets
- 23. 3 winter markets
- 24. Income $450000+ 21% gross profit margin
- 25. Income $450000+ 21% gross profit margin
- 26. Where are we going today? • A few basics • Tunnel size • Plastic Options • Rowcovers/ Low Tunnels • Inside Covers • Propagation House Efficiencies • Endwall Options • Ventilation • Movable Houses • Watering Efficiencies • Heating • Crop Economics
- 27. E-W or N-S? • whatever the grade will allow • above 40 degrees east-west • below 40 degrees doesn’t matter
- 30. Tunnel location • not under trees, shaded, power poles • protected from high winds • watch north sides of mountains • high and dry is always good- not on a flood plain • difference is summer and winter shade
- 31. drainage • a 30 X 100 tunnel will shed 1800 gallons from a 1” of rain. • where is that going to go? • drain tile buried around edge back filled with crushed stone • can drain to a cistern for reuse.
- 32. What is your tunnel for? • Winter production • washing shed • propagation house • heated production • hydroponics
- 34. High Sidewalls
- 36. 30 vs 34 ft house
- 37. 14 K 14 K 58 K Area of hoophouses 28,000 cubic ft Area of high tunnel 58,000 cubic ft
- 38. smaller houses have more edge effect 1/6.81/12.5 4500 Sq. FT 4500 Sq. FT 1 30X150 house vs 2 15X150 houses
- 39. • BIG 40 X 200 • high sidewalls/with rollups • groundheat • peak vents • metal framed polycarbonate/poly end walls The perfect greenhouse
- 40. Thermal Film (IR) Infrared heat blocking additives reduce radiant energy loss. Can block IR heat loss by half , which is 15-25% of total heat loss at night. 38 Plastic Options
- 41. Anti-Condensate Plastic (AC) Anti-fog surfactants make poly covering less repellant to water. Condensate will sheet and run down to the sides of the structure rather than bead and drop on the foliage of plants below. Condensation also reduces light transmission. 39
- 45. Solawrap • 20 + year lifespan • hail + wind proof • 1.7 R Value • diffuses light very well Picture courtesy Solawrap
- 46. Courtesy Adam Lemieux/Johnnys Seeds
- 47. Courtesy Adam Lemieux/Johnnys Seeds
- 48. Courtesy Adam Lemieux/Johnnys Seeds
- 49. Hip board- extra strip for snow shedding
- 54. Double layer or single • only reason for single is if trying to get maximum light • double helps tunnel stay more rigid • reduces heat loss by 40% • sheds snow better
- 56. Rowcover and low tunnels
- 57. What do row covers actually do?
- 58. What do row covers actually do? • Trap heat and warms the soil
- 59. What do row covers actually do? • Trap heat and warms the soil • reduce wind desiccation
- 60. What do row covers actually do? • Trap heat and warms the soil • reduce wind desiccation • cut sunscalding/burning on crops
- 61. What do row covers actually do? • Trap heat and warms the soil • reduce wind desiccation • cut sunscalding/burning on crops • keep frozen greens from thawing too quickly
- 62. What do row covers actually do? • Trap heat and warms the soil • reduce wind desiccation • cut sunscalding/burning on crops • keep frozen greens from thawing too quickly • traps moisture reduces irrigation needs
- 64. Rowcover Weights/ thicknesses • .4 oz (PRO 15
- 65. Rowcover Weights/ thicknesses • .4 oz (PRO 15 • .5 oz (PRO 19
- 66. Rowcover Weights/ thicknesses • .4 oz (PRO 15 • .5 oz (PRO 19 • .9 oz (PRO 30
- 67. Rowcover Weights/ thicknesses • .4 oz (PRO 15 • .5 oz (PRO 19 • .9 oz (PRO 30 • 1.2 oz (PRO 40
- 68. Rowcover Weights/ thicknesses • .4 oz (PRO 15 • .5 oz (PRO 19 • .9 oz (PRO 30 • 1.2 oz (PRO 40 • 1.25 oz (Typar 518
- 69. Rowcover Weights/ thicknesses • .4 oz (PRO 15 • .5 oz (PRO 19 • .9 oz (PRO 30 • 1.2 oz (PRO 40 • 1.25 oz (Typar 518 • Nursery covers
- 71. Row cover thoughts • Cheap, thin covers are not worth the money
- 72. Row cover thoughts • Cheap, thin covers are not worth the money • multiple layers trap heat between them
- 73. Row cover thoughts • Cheap, thin covers are not worth the money • multiple layers trap heat between them • hoops (ours are custom) keep rowcover off growing tips and from burning greens in the fall
- 74. Row cover thoughts • Cheap, thin covers are not worth the money • multiple layers trap heat between them • hoops (ours are custom) keep rowcover off growing tips and from burning greens in the fall • covers can increase disease pressure through trapping moisture
- 80. Mini-Tunnel Crops • Kale and Swiss Chard • Late Greens • overwintered onions
- 81. Inside Covers
- 82. Cover thoughts
- 83. Cover thoughts For maximum growth and disease suppression we’re taking the covers off as soon as they are not frozen in the morning and putting them back on between 4-5 pm
- 84. Cover thoughts For maximum growth and disease suppression we’re taking the covers off as soon as they are not frozen in the morning and putting them back on between 4-5 pm The closer the cover is to the crop the more heat retained- we don’t want it touching though
- 85. Cover thoughts For maximum growth and disease suppression we’re taking the covers off as soon as they are not frozen in the morning and putting them back on between 4-5 pm Can use either rowcover or plastic for covers- plastic may cause problems with humidity- although... The closer the cover is to the crop the more heat retained- we don’t want it touching though
- 86. From Steve Moore- note- he is in Pennsylvania
- 88. Spinach doesn’t need to be hooped and is fine with 1 layer
- 89. most of us with greens have gone to a rolling system
- 90. Rolling up the cover in the morning
- 91. Notice high sidewalls and walkway on side
- 93. covered with rowcover hoops- best to have two people to help cover- one for each end.
- 96. Our hoop houses are usually only uncovered for harvesting- remember, we are running this house as a stockpiling system
- 98. Propagation houses Richard de Wilde HarmonyValley Farm
- 101. Our Propagation House • all transplants on farm are started here in this 17’ x 48’ house
- 102. Our Propagation House • all transplants on farm are started here in this 17’ x 48’ house • air and bench heat
- 103. Our Propagation House • all transplants on farm are started here in this 17’ x 48’ house • air and bench heat • Note germination chamber on right
- 104. Our Propagation House • all transplants on farm are started here in this 17’ x 48’ house • air and bench heat • Note germination chamber on right • hose on wire and pulleys
- 105. Our Propagation House • all transplants on farm are started here in this 17’ x 48’ house • air and bench heat • Note germination chamber on right • hose on wire and pulleys • benches are covered with several layers of rowcover at night to retain heat
- 115. Germination Chambers Germination Chamber Germination chamber offers ideal environment for germinating seeds Warmth High Humidity - Auto-fill heated water pan for maintained humidity Heat a smaller space for lesser fuel inputs Ample Space Fits 20,160 - ¾” soil blocks.
- 130. Pleasant valley farm propagation house • Rollup door at end • rollup sides for hardening off and easy access to remove plants • 95% space utilization • heated, rolling benches • potting shed at end to germ lettuce, start plants • roof vent for winter venting potting shed Driveway Driveway hose manifold w/ mixing valve
- 135. Trueleaf Microgreens Designing greenhouses around an operation
- 143. Wood in a Greenhouse? • treated not allowed for organic production • cedar or locust expensive and hard to work with • 6-8 years regular wood lifespan • Metal is for life • Flaretubing is pretty cool stuff
- 148. Endwall Options photo courtesy of Pleasant Valley Farm
- 149. Endwalls • human and machinery access • Venting • necessary to keep weather out • translucent for light penetration • Utilities, systems, etc
- 150. Quincy Farm
- 154. Clearbrook Farm
- 166. Ventilation
- 168. Andre Cantelmo Heron Pond Farm
- 169. Andre Cantelmo Heron Pond Farm
- 175. Jon Satz Woods Market Garden
- 176. Jon Satz Woods Market Garden
- 184. kneewalls
- 185. Jon Satz Woods Market Garden
- 186. Movable houses
- 187. Advantages of Movable High Tunnels Multiple Season Extensions Improve Soil Fertility & Build Organic Matter Diversify Crop Rotations Minimize Insect Pressure and Soil Concerns Eliminate High Tunnel Cooling Extend Market Availability And More…
- 188. Leeks Under Low Tunnels Transplant 6 Week Old Tomatoes Prep for Leeks Carrots Under Low Tunnels Cover Crop or Summer Crop Leeks Under Low Tunnels Transplant 8-10 Week Old Leeks Direct Seed Spinach Tomatoes Finished Carrots Under Low Tunnels EMPTY, Rotate Plots for Next Year High Tunnel Warms Soil SAMPLE CROP ROTATION FOR 3-POSITION MOVABLE HIGH TUNNEL 602 Westport Rd. Kansas City, MO 64111 (816) 444-7330 SmallFarmTools.com © Four Season Tools 2010 Direct Seed Carrots Under Low Tunnels SNOW SNOW SNOW SNOW CARROTS TOMATOES Apr 1st Move, Leaving Low Tunnels TOMATOES TOMATOES LEEKS LEEKS SPINACH Dec 1st Move Over Low Tunnels Nov 1st Move Tunnel Apr 21st May 5th Jun 1st Sep 1st Dates Based on River Root Farm in Decorah, IA - High Tunnel Position 1 Position 2 Position 3 Feb 15th Move Tunnel
- 200. Watering
- 201. Watering
- 202. Winter Watering Water only to set seeds or transplants and then only when soil seems dry We water only on very sunny days and then only in the early morning. Plants need time to dry out before night.
- 203. Summer Watering most commercial growers are watering tomatoes 2-3 times a day
- 205. Irrigation Overhead Irrigation: Requires higher pressure system Drop assemblies in tunnels or sprinklers on stands for fields Mimics rainfall Can be used to water in direct seeded crops Different options for droplet size, diameter of spray, pattern of spray, and flow rate Can be manually or automatically operated
- 206. overhead watering takes the headache out of tripping over pipes on the soil surface. Rondo Mini Sprinkler
- 207. Drip Irrigation: Compatible with lower pressure systems Uses less water Provides water at root zone Not generally used for watering in direct seeded crops Different options for different flow rates and crops Can be buried or laid on soil surface Can be manually or automatically operated
- 212. Rainwater collection from roofs can be calculated using the following formulas: 1 inch of rain on a 1,000 square feet (93 m2) roof yields 623 gallons (2358 liters) of water; or 1 cubic foot equals (12 inch by 12-inch (300 mm) by 12-inch (300 mm) cube) equals 7.48 gallons; or 1 millimeter of rain on a 1 square meter surface yields 1 liter of water. 1in on 1,000 ft2 = 623 gallons 1in on 1,606 ft2 = 1,000 gallons
- 213. Richard de wilde HarmonyValley Farm
- 215. Ebb and flow benches Jericho Settlers Farm
- 219. 192 Heating
- 220. Upgrade to direct vent
- 224. Cordwood- Vermont Herb and Salad Company
- 227. “We’d easily be using 1200 gallons of oil each month”
- 228. “We’d easily be using 1200 gallons of oil each month” http://www.uvm.edu/vtvegandberry/ CaseStudies.html
- 229. Heat pumps for recovery of daytime heat
- 231. THE EXPERIMENT Green Mountain Solar Project
- 232. Total Cost $43 K
- 234. January 18 days Days with Precipitation 2010
- 235. January 18 days February 23 days Days with Precipitation 2010
- 236. January 18 days February 23 days March 15 days Days with Precipitation 2010
- 237. 204 Pete Johnson Pete’s Greens Headhouse w/ heater Greenhouse Greenhouse Air return
- 238. Biochar + Heat • James Madison University • "Wayne Teel -" <teelws@jmu.edu • Appalachian State University • David Domermuth- <domermuthdh@appstate.edu>
- 239. Winter growing is a sun driven system
- 240. • With our heat system we can raise the soil temp 3 degrees during the night Winter growing is a sun driven system
- 241. • With our heat system we can raise the soil temp 3 degrees during the night • The sun can raise the soil 5 degrees and the air 40 degrees on a mostly sunny day. Winter growing is a sun driven system
- 242. Heated Benches the most fuel efficient way to grow
- 245. Heat
- 246. Heat Constantly growing system- growth slows in December and January but doesn’t stop
- 247. Heat Constantly growing system- growth slows in December and January but doesn’t stop Less worry about cold damage
- 248. Heat Constantly growing system- growth slows in December and January but doesn’t stop Less worry about cold damage this is a growing system so covers need to be removed for light- opposed to a stockpiling system
- 249. Heat Constantly growing system- growth slows in December and January but doesn’t stop Less worry about cold damage this is a growing system so covers need to be removed for light- opposed to a stockpiling system in ground system to heat a 26 x 148 runs between five and seven thousand
- 250. air doesn’t store heat like soil does- air temp in the greenhouse will drop 40-50 degrees in a matter of hours- Soil will only loose 2-4 degrees on an average night most growers who are doing heated production are heating the soil The soil is what is actually feeding the plant- therefore more important and more efficient to heat
- 251. air doesn’t store heat like soil does- air temp in the greenhouse will drop 40-50 degrees in a matter of hours- Soil will only loose 2-4 degrees on an average night most growers who are doing heated production are heating the soil The soil is what is actually feeding the plant- therefore more important and more efficient to heat
- 252. air doesn’t store heat like soil does- air temp in the greenhouse will drop 40-50 degrees in a matter of hours- Soil will only loose 2-4 degrees on an average night most growers who are doing heated production are heating the soil The soil is what is actually feeding the plant- therefore more important and more efficient to heat Also, heating with air under covers can be quite difficult and heating the whole greenhouse (using no covers) is very expensive
- 253. Soil heat tubes are 2 ft apart 18” down
- 257. Biomass Burners http://www.uvm.edu/vtvegandberry/Pubs/ Greenhouse_Furnace_Project_Report.pdf http://www.uvm.edu/vtvegandberry/? Page=energylinks.html Energy Information Tunnel Tour Videos https://www.youtube.com/playlist? list=PLwGgmXsdmFP7H6MmOBy5eGuIT_D9d5Vaa
- 258. Crop Economics
- 269. 30” wide beds means more paths which means more wasted space
- 270. Growing for Market/Andrew Medford Tomato articles 5 single rows= 200 plants 4 double rows= 320 plants
- 271. Pre-cut groundcloth Cut X’s not round holes to reduce weeds
- 272. Pre-cut groundcloth Cut X’s not round holes to reduce weeds
- 275. bunch line greens line barrel washer vegetable washer tomato area coolers in feed
- 279. Greenhouse Manufacturers • Four Season Tools, www.smallfarmtools.com • Rimol Greenhouse Systems, https:// www.rimolgreenhouses.com • Harnois Greenhouses, http://www.harnois.com • Johnnys Selected Seeds, http:// www.johnnyseeds.com
- 280. Connect with us! @michaelkilpatrick21 Michael Kilpatrick www.kilpatrickfamilyfarm.com www.michael-kilpatrick.com