Designing your Greenhouse for Efficiency

Tunnel Efficiencies

This talk will be on my blog..

www.michael-kilpatrick.com

http://www.michael-kilpatrick.com

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.

Passionate about

Helping small farms become sustainable and effective businesses

Four season farming and season extension

Slow Tools and machinery outfitting for small farms

1/22/10 8:55 AM9778 State Route 22, Middle Granville, NY 12849 - Google Maps

Page 1 of 1http://maps.google.com/maps?f=q&source=s_q&hl=en&geocode=&q=92849&ll=42.747012,-74.256592&spn=10.937574,23.181152&z=6&pw=2

Address 9778 State Route 22Middle Granville, NY 12849

2009 Google - Map data 2009 Google, Tele Atlas -

We were in Middle Granville, NY - an hour north of Albany, NY Zone 4b

Kilpatrick Family Farm

12-15 acres in vegetables

25-30 Acres in Cover Crop

8 full time employees

1/3rd acre of Tunnels

3,000 yards of compost annually

4 Summer Markets

3 winter markets

Income $450000+

21% gross profit margin

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

E-W or N-S?

whatever the grade will allow above 40 degrees east-west below 40 degrees doesnt matter

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

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.

What is your tunnel for? Winter production

washing shed

propagation house

heated production

hydroponics

High Sidewalls

Tunnel size considerations

30 vs 34 ft house

14 K 14 K

58 K

Area of hoophouses 28,000 cubic ft

Area of high tunnel 58,000 cubic ft

smaller houses have more edge effect

1/6.81/12.5

4500 Sq. FT 4500 Sq. FT

1 30X150 house vs 2 15X150 houses

BIG 40 X 200

high sidewalls/with rollups

groundheat

peak vents

metal framed polycarbonate/poly end walls

The perfect greenhouse

Thermal Film (IR)Infrared heat blocking additivesreduce radiant energy loss. Can

block IR heat loss by half , which is15-25% of total heat loss at night.

38

Plastic Options

Anti-Condensate Plastic (AC)

Anti-fog surfactants make polycovering less repellant to water.

Condensate will sheet and run downto the sides of the structure rather

than bead and drop on the foliage ofplants below. Condensation also

reduces light transmission.39

Pete JohnsonPetes Greens

Agrotech.com

polycarbonate-Nolts Produce Supply

1-717-656-9764

www.northerngreenhousesupply.com

Woven Greenhouse Plastic

http://www.northerngreenhousesupply.com

Solawrap

20 + year lifespan

hail + wind proof

1.7 R Value

diffuses light very well

Picture courtesy Solawrap

Courtesy Adam Lemieux/Johnnys Seeds

Hip board- extra strip for snow shedding

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

Rowcover and low tunnels

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





keep frozen greens from thawing too quickly

traps moisture reduces irrigation needs

Rowcover Weights/thicknesses


.4 oz (PRO 15


.4 oz (PRO 15

.5 oz (PRO 19


.4 oz (PRO 15

.5 oz (PRO 19

.9 oz (PRO 30


.4 oz (PRO 15

.5 oz (PRO 19

.9 oz (PRO 30

1.2 oz (PRO 40


.4 oz (PRO 15

.5 oz (PRO 19

.9 oz (PRO 30

1.2 oz (PRO 40

1.25 oz (Typar 518


.4 oz (PRO 15

.5 oz (PRO 19

.9 oz (PRO 30

1.2 oz (PRO 40

1.25 oz (Typar 518

Nursery covers

Row cover thoughts

Row cover thoughts

Cheap, thin covers are not worth the money

Row cover thoughts


multiple layers trap heat between them

Row cover thoughts



hoops (ours are custom) keep rowcover off growing tips and from burning greens in the fall

Row cover thoughts



hoops (ours are custom) keep rowcover off growing tips and from burning greens in the fall

covers can increase disease pressure through trapping moisture

Mini-Tunnel Crops

Kale and Swiss Chard Late Greens overwintered onions

Inside Covers

Cover thoughts

Cover thoughts

For maximum growth and disease suppression were taking the covers off as soon as they are

not frozen in the morning and putting them back on between 4-5 pm

Cover thoughts



The closer the cover is to the crop the more heat retained- we dont want it touching though

Cover thoughts



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 dont want it touching though

From Steve Moore- note- he is in Pennsylvania

Spinach doesnt need to be hooped and is fine with 1 layer

most of us with greens have gone to a rolling system

Rolling up the cover in the morning

Notice high sidewalls and walkway on side

covered with rowcover hoops-best to have two people to help

cover- one for each end.

Our hoop houses are usually only uncovered for harvesting-

remember, we are running this houseas a stockpiling system

Propagation houses

Richard de WildeHarmony Valley Farm

Our Propagation House


all transplants on farm are started here in this 17 x 48 house



air and bench heat



air and bench heat Note germination chamber on right



air and bench heat Note germination chamber on right hose on wire and pulleys



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

Delta-T bench systemwww.deltatsolutions.com/

http://www.radiantroots.com/

www.trueleaf.net

http://www.deltatsolutions.comhttp://www.radiantroots.comhttp://www.trueleaf.net

Germination ChambersGermination 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 - soil blocks.

Paul ArnoldPleasant Valley Farm

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

Driv

eway

Driv

eway

hose manifold w/ mixing valve

Trueleaf Microgreens Designing greenhouses around an

operation

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

Endwall Optionsphoto courtesy of Pleasant Valley Farm

Endwalls human and machinery access

Venting

necessary to keep weather out

translucent for light penetration

Utilities, systems, etc

Quincy Farm

Clearbrook Farm

Pre-Fabricated endwalls

Ventilation

Andre CantelmoHeron Pond Farm

advancingalternatives.com/

http://www.advancingalternatives.com

Jon SatzWoods Market Garden

kneewalls

Jon SatzWoods Market Garden

Movable houses

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

Leeks

Under Low Tunnels

Transplant 6 Week

Old Tomatoes

Prep forLeeks

Carrots

Under Low Tunnels

Cover Crop or Summer Crop

Leeks

Under Low Tunnels

Transplant 8-10

Week Old Leeks

Direct SeedSpinach

TomatoesFinished

Carrots

Under Low Tunnels

EMPTY, Rotate

Plots for Next Year

High TunnelWarms Soil

SAMPLE CROP ROTATION FOR 3-POSITION MOVABLE HIGH TUNNEL

602 Westport Rd.Kansas City, MO 64111

(816) 444-7330SmallFarmTools.com

Four Season Tools 2010

Direct Seed Carrots

Under Low Tunnels SNOW SNOW

SNOW SNOW

CARROTS TOMATOES

Apr 1stMove, LeavingLow Tunnels

TOMATOES

TOMATOES

LEEKS

LEEKS

SPINACH

Dec 1stMove Over

Low Tunnels

Nov 1stMove 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 15thMove Tunnel

Watering

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.

Summer Watering

most commercial growers are watering tomatoes 2-3 times a day

IrrigationOverhead 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

overhead wateringtakes the headache

out oftripping

over pipeson the soil

surface.

Rondo Mini Sprinkler

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

Rainwater collection from roofs can be calculated using the following formulas:1inch of rain on a 1,000 square feet (93m2) roof yields 623

gallons (2358 liters) of water; or1 cubic foot equals (12inch by 12-inch (300mm) by 12-inch

(300mm) cube) equals 7.48 gallons; or1 millimeter of rain on a 1 square meter surface yields 1 liter

of water.

1in on 1,000 ft2 = 623 gallons1in on 1,606 ft2 = 1,000 gallons

Richard de wildeHarmony Valley Farm

Paul ArnoldPleasant Valley Farm

Ebb and flow benches

Jericho Settlers Farm

Jericho Settlers Farm

DIG controller

Rainflow.com

192

Heating

Upgrade to direct vent

Cordwood-Vermont Herb and Salad

Company

Wed easily be using 1200 gallons of oil each month

Wed easily be using 1200 gallons of oil each month

http://www.uvm.edu/vtvegandberry/CaseStudies.html

http://www.uvm.edu/vtvegandberry/CaseStudies.html

Heat pumps for recovery of daytime heat

THE EXPERIMENT

Green Mountain Solar Project

Total Cost $43 K

Days with Precipitation 2010

January18 days


January18 days

February23 days


January18 days

February23 days

March15 days


204

Pete JohnsonPetes Greens

Headhouse w/ heater

Gre

enho

use

Gre

enho

use

Air return

Biochar + Heat

James Madison University "Wayne Teel -"

Winter growing is a sun driven system

With our heat system we can raise the soil temp 3 degrees during the night


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.


Heated Benches the most fuel efficient way

to grow

Heat

Constantly growing system- growth slows in December and January but doesnt stop

Heat


Less worry about cold damage

Heat



this is a growing system so covers need to be removed for light- opposed to

a stockpiling system

Heat



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

air doesnt 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

air doesnt 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 undercovers can be quite difficult

and heating the whole greenhouse(using no covers) is very expensive

Soil heat tubes are 2 ft apart 18 down

Biomass Burnershttp://www.uvm.edu/vtvegandberry/Pubs/Greenhouse_Furnace_Project_Report.pdf

http://www.uvm.edu/vtvegandberry/?Page=energylinks.html

Energy Information

Tunnel Tour Videoshttps://www.youtube.com/playlist?

list=PLwGgmXsdmFP7H6MmOBy5eGuIT_D9d5Vaa

Crop Economics

Haukuri Turnips

Haukuri Turnips

Radishes

Radishes

tomatoes

Greens

Greens

Greens

Greens

InterplantingSwiss Chard

Boc Choi

OverplantingOnions

Micromix

30 wide beds means more paths which means more wasted space

Growing for Market/Andrew Medford Tomato articles

5 single rows= 200 plants 4 double rows= 320 plants

Pre-cut groundcloth

Cut Xs not round holes to reduce weeds

bunch line

greens line barrel washer

vegetable washer

tomato area

coolers

infeed

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

http://www.smallfarmtools.comhttps://www.rimolgreenhouses.comhttp://www.harnois.comhttp://www.johnnyseeds.com

Connect with us!

@michaelkilpatrick21

Michael Kilpatrick

www.kilpatrickfamilyfarm.com

www.michael-kilpatrick.com

http://www.kilpatrickfamilyfarm.comhttp://www.michael-kilpatrick.com

Education

Designing your Greenhouse for Efficiency