Make the headhouse the nerve center of your business

If your operation has more than a couple greenhouses, it may be time to add a headhouse. Besides providing an area to do potting, transplanting and shipping, the headhouse is an excellent place for the support facilities needed to run an efficient business. If possible, it should also serve to tie the greenhouses together providing access without having to go outside — an advantage during inclement weather.

Style - The most desirable style is a clear span, wood or metal frame building. Because it is less expensive to construct, a section of gutter connected greenhouse may be the best choice. Installing an energy or shade screen will reduce heating costs and provide for a better environment during the summer. Some growers have paid for the headhouse by growing hanging baskets overhead.

Size - The building should be long enough to connect to all the greenhouses. A minimum width of 24 feet is necessary to be able to locate equipment and still have room for moving plants. In larger operations, widths up to 60 feet are common. Ceiling height should be 14 feet or higher if a bucket loader or fork lift is used. Install a concrete floor and large overhead insulated doors for equipment access.

A “Rule of Thumb” for sizing the headhouse is:

Uses for the headhouse
Let’s look at what services and operations might be included in the headhouse:

Office - Every operation needs a private area for phone conversations, keeping records, receiving customers and giving instructions to employees. In larger businesses, it can also house the secretary, bookkeeper and sales staff. The office should be located near the main entrances to the headhouse. Allow at least 100 square feet per person that will use the room. Some growers install a large window in the office that overlooks the work area. In larger operations, the environment control computer should be located here or in an adjacent room.

Utilities - The headhouse is a good place to locate the main electric panel and water supply tanks. Its central location with access to the greenhouses keeps wiring and piping distances short. A central fertilizer injector system can also be located here.

Restrooms - Depending on the size of the operation, one or more restrooms may be needed. Connection to a sewer or septic system usually requires a permit.
 

Lunchroom - An area separate from the work area should be provided for lunches and breaks. This can be partitioned to keep out dust and odors. In large facilities space for lockers, refrigerator, microwave and sink is desirable.

Pesticide Storage - If properly designed, pesticide storage can be placed in the headhouse. The room must have continuous ventilation with makeup air brought in from outside. Identification signs and positive locking are also required. The area for mixing should be nearby.

Supply storage - Much of the smaller items (replacement parts, hardware, labels, etc.) can be stored where there is easy access and good inventory control. If the headhouse has a high ceiling (14 feet minimum) a raised storage area above some of the other rooms can be used to hold containers and other light material. Bags of growing mix, peat, and other media. usually are stored outdoors or in a vacant greenhouse. If the site allows it, an integral loading ramp with convenient access is desirable.

Cold storage – This is desirable for holding bulbs, flowering plants and produce. A prefab unit is the easiest to install.

Work Area - The remaining area in the building should be open so that it can be used for a work area. Flexibility is important as the needs change from season to season. In early spring, the space is needed for potting and transplanting. Later, when the plants are grown, more space is needed to assemble orders for shipping. Except in large operations, equipment such as the mixer and pot/flat filler should be portable so that they can be moved out of the way when not in use.

A well-designed headhouse will pay dividends in reduced labor and energy.

Bartok is a regular contributor to Greenhouse Management and an agricultural engineer and emeritus extension professor at the University of Connecticut. He is an author, consultant and a certified technical service provider doing greenhouse energy audits for USDA grant programs in New England.

Have a question? You can write John at jbartok@rcn.com.