High Tunnels for Farms Final Version

7/29/2019 High Tunnels for Farms Final Version

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Page 2 Is a High Tunnel R ight for Your Farm?

Introduction

This manual is designed to help youmake an informed decision as towhether or not a high tunnel willbenefit your business operation.We will examine marketing, humanresources, site requirements, andthe initial costs associated with ahigh tunnel. This manual may notprovide all of the answers, but itwill assist you in determining thequestions you need to ask yourselfand others. Only after examiningthe whole picture can a decision bemade regarding the addition of ahigh tunnel on your farm.

This manual should be used withthe following marketing manuals,which can be downloaded from TheLearning Store at:

http://learningstore.uwex.edu.

A3811-20 Are Farmers Marketsa Good Fit for Your Business

A3811-4 What is Community

Supported Agriculture?

A3811-5 Selling to Restaurants

A3811-19 Selling to Institutions

The Beginning

Brown County UW-Extension beganhigh tunnel trials in 2003. The firsttunnel was 12x44 and provided datafor two years. The current unit waserected in the Organic Learning Centerin 2008.


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What is a high tunnel?

High tunnels are unheated, plastic-covered structures that provide an intermediate level ofenvironmental protection and control compared to open field conditions and heatedgreenhouses. In high tunnels, seeds and transplants are planted directly into the soil ratherthan in pots or flats, or on benches or tables. Since there is no cement slab or heatingsystem, construction costs are lower with a high tunnel.

In order to determine the effectiveness of a high tunnel in our area, temperatures weremonitored at various locations both inside and outside of the high tunnel during thewinter of 2003-2004. The chart shows that while outdoor temperatures dropped to -12Fon several occasions, soil temperatures inside the tunnel under the row cover remained at

or above 28F (early February). By early March, soil temperatures were above 40F, theminimum soil temperature necessary for germination of some cool season vegetables.Air temperatures under the row covers remained above 20F until early January. As aresult, we harvested salad greens until that time and gained a very early start to ourspring planting.

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-10

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2003 Date 2004

Temp

MIN Soil Temp

B Ground Level

B Above Row Cover

C Outdoor MIN

Is a High Tunnel R ight for Your Farm? Page 3


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Every Farm is Different

Since every growers situation is uniquehe or she must look at the overaloperation in order to make an informeddecision. Market opportunitiesavailability of labor, costs, and thephysical aspects of the farm must all betaken into consideration.


Why consider

a high tunnel?

Due to its ability to provide a protectedgrowing environment without the cost ofossil fuels, the high tunnel can provideseveral opportunities for the grower. Inspring, the high tunnel can allow an earlystart for tomatoes, cucumbers, or othervegetables, thus allowing growers to befirst to market. During the early weeks

of the farmers market seasoncompetition is often limited, allowinggrowers to charge a premium.

The high tunnel can also provide aprotected environment for theproduction of salad greens. Depending ona farms location in Wisconsin, saladgreens grown in a high tunnel can beharvested for 10-12 months of the year

In either case, the high tunnel has thepotential to produce additional incomefor the grower.

A High Tunnel Can

Provide:

An early start for

vegetables

Protected environmentfor growing salad

greens in winter

Premium prices at early

farmers markets

Additional income


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Page 5Is a High Tunnel R ight for Your Farm?

Produce grown in

a high tunnel will

be of little value if

it cannot beconverted to

cash. Therefore,

markets will be

the first area to

examine.

Farmers Markets

A farmers market can be a good sales option for

producers and can be a primary source of income forfarmers who attend a number of markets throughout theweek. For those just getting involved in direct marketing,farmers markets are a great way to test the market anddetermine what customers want.

Farmers markets usually charge a nominal weekly orannual fee. In addition, you will need a canopy, tables, andsignage. This allows the grower to utilize this avenue for

marketing with very little initial investment.

Marketing

The farmers market offers exposure to a number of potential customers in a short timeperiod. If you attend these markets on a regular basis, you will also have the opportunity toestablish relationships with customers a good way to secure repeat business.

One strategy for growers is to be first to market with vegetables such as tomatoes andcucumbers, thus having the opportunity to charge premium prices. In order to takeadvantage of this opportunity, check to see when farmers markets in your area beginoperation.

Additional information can be found in UW-Extension publication no. A3811-20 AreFarmers Markets a Good Fit for Your Business.


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Community Supported Agriculture (CSA)

Community supported agriculture (CSA) refers to a

partnership between a farmer and a community ofsupporters. At the beginning of the year, supporterspurchase a share of the farms production. The farmeruses this money to cover the cost of seeds, fertilizer,equipment maintenance, and labor in order to produce ahealthy supply of fresh produce throughout the season(usually May through October in Wisconsin).


Its a great way to mitigate risk by preselling sharesearly in the year.

The high tunnel may allow a grower to offer a greaternumber of share weeks and thus charge more pershare.

The grower could offer a separate share for springsalad greens, thus increasing income.

Another possibility is to offer a winter share andcombine with stored vegetables such as potatoes,carrots, etc.

When CSA members make this commitment, they are supporting the farm through theseason and are sharing the costs, risks and bounty of growing food along with the farmer.This mutually supportive relationship between local farmers and community membershelps to create economically stable farm operations in which members are assured thehighest quality produce. In return, farmers are assured a reliable market for a variety ofcrops.

The high tunnel can offer the CSA operator several opportunities:

However, the CSA also has its own unique costs such as boxes for delivery, weeklynewsletters, packaging, etc. All of these costs must be taken into consideration.

For a more complete analysis of things to consider, see UW-Extension publication no.A3811-4 What is Community Supported Agriculture?


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Restaurants and

Specialty Shops

As competition increases among restaurants,chefs at many white linen style restaurants aremore interested in buying directly fromfarmers. This allows them to cook with field-ripened vegetables and tree-ripened fruitsdifficult to find through food brokers. Inaddition, by purchasing directly from growers,they can often find specialty items such asfingerling potatoes, heirloom tomatoes, andmuch more.

For farmers, there are several advantages toselling directly to restaurants. First, restaurantsprovide a steady market throughout theproduction season. If you are selling a qualityproduct, restaurants are willing to pay topdollar, especially for those items that theycannot find elsewhere.


Another advantage of sellingdirectly to restaurants is thepersonal relationships you can

build with owners, managersand chefs.


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Restaurants and Specialty

Shops (continued)

As with every marketing niche, there arecertain challenges. Most restaurants havelimited cooler space and therefore mayrequire deliveries several times per week.This can mean more time spent driving,invoicing, completing paper work andmore time spent away from the farm.

Another point to consider is therestaurants normal payment schedule.Unlike a farmers market where you leaveeach day with cash in hand, you may waitanywhere from two weeks to 45 days ormore before receiving payment. Therefore,product liability insurance will be anothercost to consider.

By working directly with chefs, you can

gain a marketing edge by becomingacquainted with the latest ideas and trendsin the restaurant industry, allowing you totailor your product to specifically fit theirneeds.

Additional information can be found inUW-Extension publication no. A3811-5Selling to Restaurants.



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Wholesaling

Selling your farm products to institutions

such as schools, hospitals and nursinghomes can be a very challengingyetrewardingexperience. This market givesyou the opportunity to sell large quantitiesto a few customers, thus reducing labor anddelivery costs. Sales to institutions may alsohelp to increase your sales at othermarketing outlets due to your increasedexposure in the community.

Keep in mind that institutions typicallypurchase products wholesale and, in general,expect lower prices than you would receiveat farmers markets. Selling to institutionsalso requires time and effort to establish andmaintain business relationships with foodservice managers. When dealing withinstitutions, farmers generally do not receive

payment on delivery and may need to waitas long as 30 to 90 days before invoices arepaid.

Farmers who wish to sell to institutions willalso be required to carry general liabilityinsurance. The amount of coverage variesfrom $1 million to $5 million. You will needto consider this cost, as well as delivery,production and related expenses whenlooking at institutional markets and yourpricing structure. Before entering this arena,take the time to understand the institutionalmarkets unique dynamics.


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In addition to meeting the food service director and providing samples and otherinformation, you will also be on a fact-finding mission during your visit. The informationthat you want to gather includes:

Gathering Additional Information


Having a thorough understanding of the facilitys operating procedures will give you agreater ability to successfully serve the account, build a lasting relationship, and price yourproduct at a level that will assure profitability.

More details are available in UW-Extension publication no. A3811-19 Selling to Institutions.

What is the ordering cycle? What are the receiving hours? What are the receiving days? What are the invoicing procedures? How must the product be packaged? What are the quality standards? Do they currently buy locally? What types of products would they

be interested in purchasing? What are the quantities they use per

week?


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Depending on which marketing

option(s) you choose, each willhave its own associated costs.

In order to determine pricing andpotential profit, all of these costsmust be investigated and takeninto consideration.

Marketing Costs

Human Resources

What you are growing, as well as the marketing opportunities you pursue, will determinelabor requirements. Will you be able to do the work yourself or will additional help beneeded? If needed, will labor be available at the time of year you will be using the tunnel?

If using outside labor, what amount of training anddirect supervision will be needed? Will there byany change in your current work force in the nextfew years (i.e. if family members are currentlyhelping, will any of them be leaving to attendcollege in the next few years?). Costs of outsidelabor, as well as the cost of your time, must befactored into your decision as to whether a hightunnel is right for your operation.


Marketing Options:

Farmers MarketsCSAsRestaurantsSpecialty ShopsSchoolsHospitalsNursing Homes


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Operations

Site SelectionNumerous factors will determine the initialcost of site preparation for your tunnel. Thesite you select must be level and have fertile,well-drained soil. Access to water will be anecessity since plants will need to be irrigatedthroughout the growing season. If you will begrowing early in the season, an undergroundline with a frost-proof hydrant may be

necessary.

Another consideration will be power. Ifutilizing a double-layer cover, then electricitywill be needed for the inflation fan. Largertunnels may also require power for ventilationfans. The site selected will need to beaccessible in the winter so that accumulatedsnow can be removed from the top and sides

of the structure. All of these costs must befactored into your decision.

Site Selection is

Important:

Area must be level Fertile soil Good drainage Water Power Accessible in winter


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Cost of Tunnel

Many high tunnel vendors offer only

the frame of the structure. Inaddition to the frame and its relatedshipping cost, many other costs,such as end walls, doors, etc. mustbe taken into consideration. Thecost of the end walls will bedetermined by the size of thestructure as well as the type ofmaterial used. End walls can be

covered relatively inexpensivelywith 6 mil greenhouse plastic, ormore expensive (and morepermanent) options such asexterior grade plywood or clearpolycarbonate panels.

End walls are often framed with2x4s using 24 centers since theyare not load bearing walls. Manygrowers use 4x4s on either side ofthe doorways. The cost of thelumber to frame the end walls willbe dependent upon the width andheight of the tunnel.

Other Lumber costs: 2x12 lumber (or two 2x6s stacked side by side) will also be neededfor kickboards at the base of the frame. This lumber will be in constant contact with thesoil. Therefore, this must be taken into consideration when selecting the type of wood to

use. Cedar lumber will last longer but at a much higher cost. The hip boards on the sides ofthe tunnel can be constructed with 2x6 lumber since they will not be in contact with theground.

Doors: The type of doors you install will be determined by the type of equipment you planto use in the tunnel. A small tractor may require an overhead door or large double doorswhile a much smaller door can accommodate a rototiller. Therefore, cost of doors will varyfrom grower to grower.


Hip Board

Kick Board


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Insulation

Many high tunnel operators who focus on winterproduction insulate the base of their structure with2 foam insulation. This allows soil temperatures tobe maintained at an elevated level inside the tunnellonger into the winter. The insulation is attached tothe ground posts and extends 2-4 feet below the soilsurface.

Other Cost Considerations

Ventilation

Ventilation is very important to prevent death ofyour plants due to high temperatures or increasedchance of disease due to high humidity levels.Ventilation will be especially critical in the early

spring. Outdoor temperatures can fluctuate betweenthe 40s and 70s while temperatures inside anunventilated tunnel could exceed 120F .

Poly Cover

The high tunnel is usually covered with a 6 mil greenhouse poly that contains a UV-inhibitor. Most greenhouse plastics are guaranteed for four years but can last longer ifproperly installed. Many growers who use a two-layer poly with an inflation fan see fiveyears of use before the poly must be replaced.

Solar powered vent fan


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Ventilation(continued)

There are a variety of methods availableto provide ventilation to your high tunnel.The size of the tunnel, the amount of timeyou are available on site, and the amountof money you want to invest willdetermine the method chosen.

The simplest method of ventilation is theuse of manually-operated vents in the

end walls and by opening and closing thehigh tunnels doors.

Many high tunnel owners install roll-upsides in order to provide ventilation. Mostroll-up sides can be raised either partiallyor up to the hip board. Automatic roll-up sides, which are thermostaticallycontrolled, can also be installed at agreater cost.

In smaller tunnels, thermostaticallycontrolled solar powered attic fans ortemperature activated openers, such asUnivents attached to louvered vents orwindows, can provide ventilation. Theadvantage of these devices is that thetunnel will be automatically ventilatedwhen no one is available to open doors.

Ventilation fans can be used to increaseair circulation around plants. However,this will result in higher initial costs aswell as higher operating costs.

Louvers with Univent

Hinged window with Univent

Roll-up sides


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Fastening Poly to Frame

Another cost is the channel used to securethe poly to the frame. This channel usuallyhas a spring wire, which secures the polyto the channel. If used, the channel will beattached to the entire length of each of theend ribs as well as the length of each kickboard.

If roll-up sides are being installed, then adouble row of channel must be attached tothe hip board. The upper channel keepsthe cover taut while the lower channel

allows you to replace only the side plastic ifit is damaged by tools or the wind.


Bracing and Support

Check with the manufacturer of the high tunnelframe, but most tunnels wider than 20 feet willrequire some type of internal bracing.

Many manufacturers suggest cross bracing onevery other rib. However, if you plan to trellisplants such as tomatoes and cucumbers, you maywant to consider installing cross braces on everyrib. This will allow more places to attach yourtrellis material.

Poly can also be attached to the kick board and end walls (depending on materialselected) using wooden lathe strips and screws. However, care must be taken that thepoly does not pull from the screws during high winds.

Spring Wire


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Other Costs

Weve covered many of the major material

costs, but there will be other costs such asfloating row covers, supports for rowcovers, hardware, thermometers, etc.

While most growers are do-it-yourselfers,extra labor may be required when erectinga tunnel. If so, this cost must also be takeninto consideration.

Calculate all costs to get the true picture.The worksheet on page 19will help you toestimate the total cost of erecting a tunnel.

Putting it All Together

Now its time to analyze all of the variables: What market(s) did you decide to pursue? What price can you reasonably expect to receive for your product in that

market and what quantity of vegetables do you anticipate selling? What will be the gross income (quantity x price)? What operating costs will be incurred (delivery, labor, etc.)? What anticipated amount of annual income will the high tunnel generate?

Compare

How does this compare to the investment you will make to purchase and erect a tunnel? Isit worth it? Like any other addition to your farm, it needs to create a return on yourinvestment of time and money.


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Cornell High Tunnelshttp://blogs.cornell.edu/hightunnels/

High Tunnels.ORGhttp://www.hightunnels.org/

High Tunnel Raspberries and Blackberries http://www.fruit.cornell.edu/Berries/bramblepdf/hightunnelsrasp.pdf

Greenhouse Raspberry Productionhttp://www.fruit.cornell.edu/Berries/ghrasp.pdf

Penn State Center for Plasticulturehttp://plasticulture.psu.edu/?q=node/2

Midwest Season Extensionhttp://midwestseasonextension.org/default.htm

The Hoophouse Blog

http://hoophouse.msu.edu/blog/index.php

Undercover Research: Growing Sweet Cherries Under High Tunnels in Michiganhttp://www.cherries.msu.edu/pdf/OrchardShow09G-Lang.pdf

Michigan State Student Organic Farmhttp://www.msuorganicfarm.org/home.php/

Resources

Here are some other sources that may provevaluable in evaluating the addition of a hightunnel to your farm.


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Cost of site improvement:

Water

Power

Site Prep

Cost of high tunnel kit

Delivery

Insulation for base (optional)

End walls:

_____ 2x4 @ each

_____ 2x6 @ each

_____ 4x4 @ each

Doors

Ventilation fans (optional)

Vent openings, etc.

Roll-up sides

6 mil poly cover (single or double layer)

Channel to attach poly

Hip board _____ 2x6 @ each

Kick board _____ 2x12 @ each

Cross braces _____ @ each

Miscellaneous:

Row covers

Row cover supports

Hardware (strapping, screens, nails)

Labor to erect structure

Total Cost


Work Sheet


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Bill WrightCommunity Garden CoordinatorBrown County UW-Extension1150 Bellevue Street, Green Bay, WI 54302Phone: (920) 391-4658Email: [email protected]

Is a High Tunnel Right for Your Farm? is a project of the Cooperative Extension EmergingAgricultural Markets team. The teams work is supported in part by a USDA grant (AgriculturalEntrepreneurship-Wisconsin). For more information on the teams work and Wisconsins newagricultural markets, visit uwex.edu/ces/agmarkets/.

An EEO/AA employer, the University of Wisconsin-Extension, Cooperative Extension provides equalopportunities in employment and programming, including Title IX and Americans with Disabilities(ADA) requirements

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