high tunnel crop management, automation & marketing

High Tunnel Crop Management, Automation & Marketing Feb 4 2012

• Scenic Valley Farm

• Scenic Valley Green Energy

• High Tunnel Overview

• High Tunnel Management

• Marketing

• SHARE-d Farm

Overview

• Designs and manages high tunnels, climate control systems, and solar thermal heating technology

• Five high tunnels in Minnesota and Wisconsin

• Produces organically certified tomatoes, peppers, blackberries, raspberries, herbs, and leafy green produce

• Decades of agriculture and engineering experience

Scenic Valley Farms

Scenic Valley Green Energy • Solid, long-term investment

• Generate income from electricity

• Promote sustainability by reducing C02 emissions

• Gain energy independence and protection from volatile electricity prices

• Offset tax liabilities

Affordable, Clean Energy from Small Wind Turbines for Homes, Farms, Businesses, Public Facilities and Investors

• Hybrid of open field and greenhouse production

• Non-permanent structures • Less expensive than

greenhouses • Crops planted in ground to

ensure superior taste • Create 12 month growing

season • Constructed with steel hoops,

covered with heat retaining, light dispersing, anti-drip plastic

• Plastic efficiently rolled up and down to manage air flow

• Drip irrigation optimizes water and natural fertilizer inputs.

• Versatile in size and shape • Incentives available at Federal

and State levels

High Tunnel Agriculture

• Boost fruit and vegetable yields up to 400% compared to field grown produce

• Steady, reliable supply of organic produce • Purchase produce at wholesale distributor rates • Harvest and deliver fruits and vegetables at

optimum ripeness and flavor • Create a year round growing environment • Meet consumer demand on either end of the

production curve when competition is lower and prices are higher

• Harvest ≈ 95 percent grade A fruit and vegetables • Meet the increasing demand for locally grown

produce • Grow healthier, safer produce with less risk of

contamination • Cost effectively expand the scale of organic farming • Shorten shipping distances = lower freight costs • Create new regional produce

Economic Benefits of High Tunnels

• Shorter distance to market cuts fuel usage

• Solar power reduces carbon emissions

• Drip irrigation conserves water • Natural compost replenishes the soil

• Organic mulching reduces erosion

• Synthetic pesticides and fertilizers eliminated

• Crops protected from climate and weather extremes

• Disease, pest, and insect control inputs reduced

• Respond to water shortages in other regions of the country

Environmental Benefits of High Tunnels

• The University of Minnesota Southwest Research and Outreach Center (SWROC) conducted field study to compare organic high tunnel vegetables to outdoor grown varieties

• SWROC high tunnels in study did not utilize auxiliary heat.

Increase Produce Yields

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SWROC 2009 Tomato Harvest: High Tunnel vs. Outdoor

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SWROC 2009 Bell Pepper Harvest: High Tunnel vs. Outdoor

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Increase Produce Yields

• Yields typically 200-300% higher in high tunnels

• Our organic determinate tomato yields in 2011 = 20 lbs per plant

• Established goal of 25 lbs/plant in 2012

SVF high tunnels equaled yields at University of Minnesota Southwest Research and Outreach Center (SWROC)

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SVF Weekly Determinate Tomato Harvest (2011)

SVF High Tunnels

Total = 19.5 lbs per plant

Increasing Produce Yields

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SVF Weekly Determinate Tomato Harvest (2011)

Conventional HT

Solar Thermal HT

End of Year Total Conventional = 9 lbs per plant Solar Thermal = 18 lbs per plant

• Solar Thermal high tunnel warms soil and air → higher yields (see chart at left)

SVF solar thermal outperformed conventional high tunnel

• High tunnel grown raspberries at the University of Minnesota, Rapids High Tunnel Research Centers

• High tunnels used drip irrigation and auxiliary propane heat to protect against frost damage

Increase Yields

Yields of two raspberry varieties in field and high tunnels (University of Minnesota, Morris)

Extending the Season

Blackberry photos taken November 14th at Scenic Valley Farms in Rosemount, MN

Create a Year Round Season

Spinach Harvested on January 15th

Ripe Gold Medal Heirlooms on November 4th

Winter Spinach under Row Covers

Extend the Growing Season

High tunnel versus outdoor grown early season extension (University of Minnesota SWROC)

• Meet consumer demand for local fruits and vegetables on either end of the production curve when competition is lower and prices are higher.

• USDA terminal market prices for produce generally higher in the early and late season months.

Extend the Growing Season

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USDA Terminal Market Price (Chicago) Vine Ripe Tomatoes

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Improves Produce Quality

Tomatoes planted at same time in spring

High Tunnel Grown Outdoor Grown

Summer blackberries in SVF high tunnel

Tomatoes in SVF high tunnel

Heirloom bell peppers in SVF high tunnel

• High tunnels produce crops not able to grow unprotected in a region, diversifying the farming system and creating new value added industries.

• SVF testing the viability of growing blackberries in a zone 4 hardiness zone

• Dr. Vince Fritz, a University of Minnesota horticultural research scientist is conducting field studies on the medicinal properties of ginger grown in high tunnels.

• Penn State University grows exotic heirloom fruits and vegetables in research high tunnels and then markets them on-campus.

Create Diversity of Regional Produce

Suitable Crops for High Tunnels

• Cucumbers • Berries • Beans • Onions • Flowers • Peppers • Blackberries

• Strawberries • Watermelons • Tomatoes • Herbs • Cherries • And Many More

Suitable Crops for Hardiness Zones 2-4

• Any crop that can normally be grown in the zone

• Most crops suitable for zone 4, 5, 6, and some 7

• If supplemental heat provided, zone 6 and beyond

Ideal for Organic Agriculture

– Higher yields offset more labor intensive practices

– Plastic barrier control disease and pest outbreaks

– Weeds easier to manage

– Natural compost applied early in year

– Liquid organic fertilizer fed through drip irrigation

– Increases percentage of high quality fruit and produce

– Biological controls thrive in controlled environment

High Tunnel Research Sites in Minnesota

Experiment Stations

Grower Cooperators

Importance of High Tunnel Selection

Research a tunnel that fits production size, handles snow load, accommodates blackberry row height, and fits budget.

• Gothic peak on 12’ X 30’ X 96’ tunnel handles snow load well

• 4-6’ straight sides accommodate outside bramble rows

• 6’ straight sides to maintain adequate ventilation

• Use 6 mil poly covering AC/IR

• Recommend using double layer poly with air space inflated by fan

Types of High Tunnel Management

• Manual

• Semi – Automated

• Fully Automated

Manual Management

• Traditional Definition of High Tunnel Management – No electrical service – No active ventilation – No heating system. – Ventilated by manually rolling the sides up or down as needed using a roll

bar. – Covered with a single layer of 6-mil greenhouse plastic structure year

around and normally lasts four years – Heavy row covers provide frost protection. – No sensor controlled irrigation system

• Drawbacks – Not monitoring high tunnels on a daily basis can result in disaster – Excessive heat builds up in hours, sometimes minutes – Common for air temps to reach 120 F in March – Over or under watering can go undetected

Semi-Automated Management

• Multiple controllers

• Multiple sensors

• Saves labor

• Reduces risk

• Requires more installation time

• No real time data feedback

• Grower not notified of device failure while off site

Ventilation and Circulation

• Exhaust fans mounted into end walls • Motorized winder on side walls • Both devices thermostatically controlled • Hayloft style doors in end walls

Irrigation System • Installed drip irrigation

• Emitters within 8” on either side of bramble

• Each emitter releases ½ gallon per hour.

• Semi automated system • Sensor and controller provide 6

zones with 6 irrigation times per zone

• Sensor provides moisture content (%), soil temperature, and EC

• Irrigation cycle suspended above pre-set soil moisture content

• Irrigated in 1.5 hour cycles at 7 am and 6 pm

• Irrigation increased to three 1.5 hour cycles during fruiting

• Installed EZ Flow (1 gallon) inline fertigation

system • Applied organic liquid fertilizer containing fish

• Fish Aqua – OMRI approved • Discovered fish emulsion based fertilizer clogs

emitters • Drip tape not clogged by emulsion but emitters too

close = wasted water and fertilizer • Install drip tape future high tunnels • Plan to fertigate one times per week • Perform soil analysis beginning and end of season,

leaf analysis during growing season

Fertigation System

Automated Management

• Combines controllers for circulation, ventilation, irrigation, fertigation, and heating

• Programmable Logic Controller wireless to a PC

• PC wireless to internet

Environmental Management System (EMS)

• Automated climate control system for high tunnels

• User monitors and controls the climate from touch screen PLC, laptop, or Smart phone

• Ventilation, irrigation, and heating are monitored and controlled on-site or remotely

• SVF awarded $100,000 USDA Small Business Innovation Research Grant

• Testing at SVF high tunnels in both Minnesota and Wisconsin

• Expected operational date: March 2011

• Potential SBIR Phase II Commercialization Grant in 2013

Environmental Management System (EMS)

High Tunnel Sensors air temperature motion soil temperature video humidity water flow soil pH soil water content TDS/EC light intensity

Production Processes Controlled heating cooling ventilation circulation irrigation fertigation security surveillance

Early Development Screenshots

Solar Thermal Heating

• Solar panels collect heated air • Fans circulate heated air below

ground • Warms soil and air temperatures • Extends growing season to allow

for additional crops and harvests • Reduces propane fuel usage and

greenhouse gas emissions

• Qualifies for 30 percent Federal Investment Tax Credit • Reduces active

income tax liability

• Three 30’x96’ high tunnels in Readsown, WI

• HT1 - conventional with single layer

• HT2 - solar thermal (ST) with double layer

• HT3 - conventional with double layer

• Use temp data logger to record temps every 30 minutes, 24/7

• Research Nov 2011 to present

• Temp data logger in soil, inside tunnel, outside

• Periodic reading of logger data

• Soil data logger in HT2 failed in May 2011

High Tunnel Temperature Research

Data Logger Conclusions

• Double layer raises night time air temp ≈ 7F • Solar thermal with double layer raises night time air

temperature ≈ 20 degrees F • Solar thermal soil temp reaches 55F by March 15th. Even

sooner with double layer • Tomato Planting times

• Outside May 23 • Conventional HT April 10 - some heat • Solar Thermal HT March 15 – some heat

• Last day to harvest Tomato • Outside Sept 23 • Conventional HT Oct 23 – some heat • Solar Thermal HT Nov 24 – some heat

Economics

Manually Semi-Auto

Automated

High tunnel (30’x96’) , not including installation, double layer, incl shipping

$9600 $9200 $9200

Irrigation and controller, trellis, fertigation tank

$1100 $1400 $1100

Plants $400 $400

End walls, side boards, door hardware, screws

$800 $800 $800

Motorized rollup sides w/thermostat $900 $300

Heater w/thermostat $350 $250

Ventilation & Circulation w/thermostat $650 $550

Plastic mulch $300 $300 $300

EMS $5000

Total Fixed Expenses $12200 $14000 $17500

Income (tomatoes, peppers, spinach) $20000 est $36380** $45811* **

•with solar

thermal

**See cash flow hand out

Estimated Return on Investment

The farm responds to…. • The increasing consumer demand for local and organic fruit and

vegetables

• The building movement to invest locally in sustainable agriculture and clean energy

• Rising oil prices (petroleum is used in agriculture for shipping, fertilizers, pesticides, herbicides)

• Producers wanting to extend the growing season in colder regions

• Consumers demanding safer, healthier fruits and vegetables with less risk of contamination

• Current and future water shortages in California and the Southwest

• Wholesale producer buyers need to shorten shipping distances and reduce freight costs

• The global effort to reduce greenhouse gas emissions

• The produce industry’s need to adapt to climate and weather extreme

Market Drivers

Current Markets

• Grocer Cooperatives

• Wholesale Dealers

• Restaurants

Market for the Farm’s Produce

Potential Markets • Supermarkets/Retail

Outlets • Community Supported

Agriculture (CSA) • Farmers Market’s • Value Added Products • Schools and Universities

Survey sent to current and

potential produce buyers

• Web based e-commerce

• Provides up to date information on fresh produce for sale

• Orders processed by credit card, check, or money order

• Buyers communicate order notes to producer

• Designed for wholesale buyers, restaurants, grocer co-ops

• Open to registered users who complete a profile

• Orders also placed by phone, fax, and email

Online Produce Market

Sustainable High Tunnel Agriculture + Renewable Energy (SHARE-d) High Tunnels

• Joint venture high tunnel greenhouses

• Environmentally and financially sustainable

• Provides reliable supply of locally grown, organic produce

• Excess produce sold on the open market

• Harvest fruits and vegetables at optimum ripeness and flavor

• Increases yields and extends the growing season

• Merges the technologies to earn a rapid return on investment

Sustainable Agriculture. Clean Energy.

Contact Us

Craig Gundacker (612) 961-3871

cegundacker@scenicvalleyfarms.com

Erik Gundacker (563) 650-3654

gun@usinternet.com

www.scenicvalleyfarms.com