How to develop a greenhouse facilities master plan

Whether you are starting a new greenhouse operation or expanding an existing one, a facilities master plan should be part of the framework for the business. The facilities master plan looks at topography and drainage, the location of buildings and outdoor growing areas, parking for customers and staff, access for vehicles and equipment, and utilities, including water supply and electricity.

The plan should also project what the business could look like in five to 10 years. Where can additional production houses, outdoor growing areas and accessory buildings be located to have good materials handling and access? Without planning, it becomes difficult to have efficiency of operation.

Review your business plan

The facilities master plan must be based on a sound business plan. What are the short- and long-range goals of your business, and how will expansion help you achieve these?

Any renovation or expansion should be set by the ability of the business to carry the cost. Your business plan and master facilities plan should complement each other by enhancing efficiencies and reducing costs.

Consider facilities requirements

Based on the goals and objectives of your business, you should establish a list of facilities requirements and a timetable for achievement. These should include:

• Amount of land available (minimum 3 acres for retail or 5 acres for wholesale)
• Amount of greenhouse expansion (current or projected)
• Amount of desired mechanization or automation
• Shipping methods
• Type of support facilities
• Environmental concerns to address.

Evaluate the alternatives for each of the above. How will these impact the cost of construction and operation? For example, the more you automate, the lower your labor costs, but the higher your construction costs.

Complete a site evaluation

Start the master plan with a topographic surveyed map of the land and existing facilities. This survey should show:

• Land elevations in 1- or 2-foot intervals
• Road access, utilities and required setback distances
• Soil types, ponds, streams, wetlands and the flow of runoff
• Property lines, neighboring structures and anything else that can affect your construction.

Existing structures should be evaluated based on functional requirements and cost. Existing buildings that are not very functional or obsolete may hinder the development of an efficient operation.

Plan your development

In developing the master plan, it is best to plan on paper, looking at several alternative layouts. The master plan starts with a survey of existing facilities, evaluating the benefits and constraints of the site and establishing how renovations should be made and where new facilities should be built.

Because materials handling is the largest cost in most greenhouse operations, consideration should be given to placement of new structures and their relation to the headhouse. The type of plant moving system selected is important in relation to the plants grown, distance moved and elevation differences. Conveyors, carts and pallet trays have advantages and disadvantages that you must evaluate.

The size of individual growing units (greenhouses or number of bays of a gutter-connected house) should be based on the quantity of plants you grow and the environment they require. Individual hoophouses may work well for an operation growing specialty plants that require different temperatures, but larger, gutter-connected greenhouses are generally more efficient for wholesale operations.

Do you need a headhouse?

If the operation has more than a couple of greenhouses, a headhouse should be a key part of the plan. Besides providing an area for potting, transplanting and shipping, the headhouse is an excellent place for the support facilities needed to run an efficient business. It can also serve to tie the greenhouses together by providing access without having to go outside, an advantage during inclement weather.

Other functional parts to consider

Office: Every greenhouse business needs a private area for phone conversations, keeping records, receiving customers and giving instructions to employees. In larger operations, it can also house the secretary, bookkeeper and sales staff.

Utilities: The headhouse is a good place to locate the main electric distribution panel, water supply pressure tanks and phone box. Its central location with access to the greenhouses and other facilities shortens wiring and piping distances.

Employee facilities: This should include a breakroom, restrooms and locker area.

Storage: Both indoor and outdoor storage is needed for materials, supplies, equipment and vehicles.

Heating plant: A central heating plant may be desirable in a larger facility to reduce operating and maintenance costs. The fuel storage should be nearby. Floor or suspended unit heaters work well in hoophouses.

Access: Driveways to all buildings should be provided for emergency use. Location and slope are important.

Maintenance shop: An area or building for storage of tools and equipment repair could be provided.

Drainage: A drainage system that will handle the large amounts of water that will come off your greenhouses and driveways is needed. You may have to construct a sedimentation pond.

A master plan can also help in obtaining zoning and wetlands permits. You should submit it with the initial phase. This then becomes part of the approval process. If commission membership and sentiment change, the expansion phases are already on file. This has been important for several growers in Connecticut who were challenged as expansion progressed.

For more information, check out "Creating a Master Plan for Greenhouse Operations" by A.J. Both from Rutgers University here: bit.ly/greenhouse-master-plan.