When Is Retrofitting the Right Move for Your Greenhouse Design?
Deciding whether to retrofit an existing structure or build a new greenhouse must lead to an answer that aligns with your business goals. It’s not a matter of short-term preference. This decision is concerned with long-term business sustainability, which is why we often say: Start with the end in mind.
Let’s begin with simple definitions, though.
First, understanding what comes with retrofitting is important. Unlike new construction, retrofitting involves restructuring the current design aspects of a structure, such as glazing, ventilation, shade systems, and environmental controls.
For instance, adding shade systems can be valuable depending on the regional climate. Introducing thermal curtains can protect your crop by reducing heat loss during cold winter months. Additionally, they can also help control greenhouse temperatures and humidity levels on especially hot or sunny days.
In some cases, growers can obtain utility rebates to lower the costs of implementing energy-efficient technologies. Some of these changes are also relatively quick fixes, requiring only a few days or weeks to complete.
Below are examples of what may be included when retrofitting a greenhouse:
- Changing the coverings
- Adding passive ventilation
- Resealing all entry points
- Adding shade systems
- Upgrading environmental controls
- Upgrading plumbing systems
- Replacing irrigation
- Replacing old benching
- Updating electronic monitors
- Incorporating blackout curtains
The Benefits of Retrofitting
Rebuilding is an extensive process that may not be possible for everyone. Perhaps your company has landed a cost-effective piece of real estate, and you’re considering using an existing structure for your CEA needs.
Retrofitting what you have on hand may be easier than building new right out of the gate.
With a new build, going over budget can be easy when creating an up-to-code, energy-efficient, and top-of-the-line structure. Breaking new ground often means more time and labor, further driving up costs. In these situations, retrofitting offers a more affordable, comparable approach that still presents ample space for customization and efficiency.
Below are some advantages of retrofitting a structure for your greenhouse needs:
- Less expensive than a new build: Designing and building a new greenhouse involves engineering, electrical work, new plumbing systems, and many other costs. Retrofitting your greenhouse offers a less expensive way to reduce energy, heating, and supply expenses according to priority, needs, and desired outcomes.
- Improved product yields: Simply improving ventilation, shades, or benches can boost crop yield. For example, rolling benching offers more greenhouse space, while polycarbonate provides better insulation to reduce heating expenses.
- Working with familiar spaces: Over time, you get accustomed to the layout, ventilation, and overall environment of your greenhouse. Retrofitting allows you to build on these aspects without becoming overwhelmed by learning about and adapting to entirely new systems.
- More environmentally friendly: Retrofitting a greenhouse can help reduce building and carbon emissions up to 50-75%.
But What About a New Build?
Retrofitting is a great option in greenhouse design. However, in some cases, creating a new structure may be necessary.
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Your current greenhouse may require extensive construction to meet ideal energy, plumbing, ventilation, or space needs. Rebuilding (or building new in the first place) offers full customization for optimum plant growth, product yield, and overall performance.
Below are some advantages of a new build when designing a greenhouse:
- More customization: Rebuilding a greenhouse means you can pick and choose exactly what systems or materials suit your needs.
- Reduced construction time: Sometimes, retrofitting a greenhouse with new benching, heating, or roofs can be more time-intensive in the long run than building new, especially when you consider potential downtime for your operation. New construction also means not having to work around planted crops.
- Increased productivity: Using top-notch materials and technology can reduce difficulties associated with outdated equipment, thus improving productivity, yield, and overall product quality.
- Better layout/efficiency: Using an older greenhouse with an inefficient layout can pose many problems. Rebuilding a greenhouse helps address possible safety concerns or barriers impacting productivity or yield.
How to Decide Whether to Retrofit or Build New
Once you understand the basic trade-offs of retrofitting or building new, you can start identifying goals and which method will help you obtain these outcomes. Work backward from your end goal to ensure you don’t lose sight of what you truly want out of your facility.
Any large greenhouse expansion or complete demolition requires time, so preparation is essential for continuing production throughout the construction process.
Here are a few things to consider before deciding to retrofit an existing greenhouse or build a new one:
- Determine your end goals (start with the end in mind): What will a retrofit or new build provide you? Do you want to improve production or reduce energy costs? Determining these goals will help you assess which approach yields the best results.
- Build a comparative budget/timeline: As with construction, creating a budget and proposed timeline is crucial. Unexpected costs can quickly derail a project, and setbacks can cut production time. Stay ahead by making a comparative list of the pros and cons associated with retrofitting or rebuilding your greenhouse.
- Identify key issues to address: Examine which elements of your greenhouse need work. A retrofit may be best if you want minimal changes, while a new build is ideal for substantial projects.
- Explore future expansion opportunities: Do you plan to increase yield or start growing additional crops? Consider if space expansion (i.e., rolling benches or new square footage) is possible in your current layout or if new construction may be necessary.
- Examine your current layout: As mentioned above, an efficient greenhouse layout is important for product yield. Retrofitting may be feasible if you have the space for reformatting. In other cases, a new build can address dysfunctional design elements,
- Identify any structural issues: Rebuilding a greenhouse may be more financially realistic than retrofitting one with a poor foundation, roofing system, or overall structure.
- Look for possible environmental hazards: Some older greenhouses were constructed with lead paint or asbestos. In these cases, rebuilding may be necessary to eliminate environmental hazards.
- Examine potential utility cost differences: Reducing energy and heating costs with an older greenhouse may be more expensive than starting from a fresh slate.
How to Get Started With a Retrofit or New Build
An extensive project like retrofitting or rebuilding a greenhouse requires experience and expertise in the field. Whether you work with your current structure or seek a new one, ensure to choose a design partner with the necessary qualifications, and knowledge. You should also be familiar with the local regulations, as these requirements can change.
Remember, maintaining a greenhouse is a constant, ongoing job. Investing time and money into your structure can be daunting, but conducting thorough audits of your needs can help reduce the likelihood of additional projects in the future. Moreover, finding professionals who care about and cater to your goals can take a load off your shoulders as you grow and expand.
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