This document summarizes the design of an 18 ha commercial tomato greenhouse in three phases. It describes the client's philosophy of minimum energy and water use without pesticides. The design includes greenhouses, a headhouse, technical building, irrigation and heating systems, lighting, cultivation system, and post-harvest facilities. The goal is an efficient, economical, and sustainable tomato operation meeting the client's needs and philosophy.

1. Presentatie project
Turnkey greenhouse
VEK Adviesgroep BV
How to design and construct
a 18 ha commercial nursery?

2. How to design and construct a 18 ha commercial nursery?
VEK Adviesgroep was assigned to develop a nursery, together with the client, with the starting point that the nursery should comply
with the philosophy of the grower. This philosophy is based on a minimum use of energy, a closed water circulation system without
discharge, growing tomatoes without pesticides in an economical efficient way, good facilities for the staff, a modern shipping building
with efficient logistics.
Moreover, the company has to be designed in such a way that phase 2 can be realized without any problems and the water technical
installation and the hot boiler room are prepared for extension with a minimum of effort.
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3. Sustainability and economy
Today, tomatoes are grown more and more without the use of any chemical pesticides. Moreover, research showed that within
the rock wool on which the tomatoes grow, an important biological life prevails. Because the rock wool is reused annually,
eventually this results in a balance between good and bad fungi. This balance helps to ensure that it is no longer necessary to
use chemical pesticides.
Because of these experiences, a total new way of growing tomatoes is developing. Any interference in the greenhouse affects the
natural system. The plants, fungi, bacteria, the roots, the climate, everything has an influence on each other. The big difference
with the traditional way of growing is that the system is not broken down when there is a problem. One continues to work within
the existing and natural system. The interventions are aimed to maintain and strengthen the system. This way, the system will
eventually have the power to solve the problems itself.
The objective is to produce the best and most tasteful tomatoes with a minimum of resources and waste.
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4. Why choose VEK as your Turnkey Greenhouse Partner?
Our specialists have over 4 decades of experiences in greenhouse
design, constructions and installations, both domestically and
abroad. We are experienced in both glass and poly houses for
vegetables, flowers, pot plants and bedding plants.
VEK Adviesgroep offers its customers a greenhouse facility that is
suitable for the local climate and meets the client’s expectations.
How we accomplish this, is based on a triangle of knowledge in
growing and technology, experience and implementation.
Our approach contains 4 unique steps:
7) Design
8) Tender
9) Construct
10) Training & Greenhouse Management
VEK office
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5. Why choose VEK as your Turnkey Greenhouse Partner?
• Design
Design plays a crucial role in the success of each greenhouse project. With VEK Adviesgroep the crop is ‘king’. This means that
the whole concept and design is executed in the interest of the crop. VEK Adviesgroep incorporates information on local climate
conditions and circumstances, possible energy concept, cooling or heating requirements, availability and quality of water, the
growing skills of the management and labourers, marketing opportunities for the crop etc.
Objectives during this process are:  Functionality and efficiency
 Sustainability
 Economics
VEK Adviesgroep underlines the importance of this phase of a project. Accordingly, we have a team of engineers and designers
who are looking for the most functional design to be able to grow the best quality product with the best possible yield in the given
local circumstances.
• Tender
Through our global network of suppliers we are able to provide unbeatable prices through a system of competitive tendering for
worldwide specialized builders and suppliers. The Design & Construct method of VEK Adviesgroep works with open book
calculations, so you get access to the budgets and the entire project is transparent .
13) Construct
VEK Adviesgroep is experienced in managing the whole process and is responsible for the complete construction period. Our
goal is to build according to your requirements and to finish our work in time. Through our global network, we are able to select
the best builders and suppliers for your project with a proven international track record.
16) Training & Greenhouse Management
A good design, selecting the right suppliers and a well managed building period do not guarantee high quality products and
yields as were envisaged. Training and education of employees, staff and management are essential. They have to learn how to
deal with the new equipment, techniques and grow methods.
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6. Design stage
The objective of the company is to realise a greenhouse complex in two phases of 18 ha in total for the cultivation of snack
tomatoes. The starting point was a complete new horticultural area for the construction of modern greenhouses.
Requirements of the client:
• Site development
• Realization of utility connections because these large capacities were not available in the area
• Greenhouse
• Possibilities in the greenhouse to use the new way of growing according to the philosophy of the client
• Automatic glass cleaning system
• Packing building with 2 loading docks
• Unique screening installation
• Shielding of the grow light
• Grow light installation
• Closed water circulation system, including reuse of the condensation of the CHP system
• Energy production and supply to the electricity grid
• Year round water storage by means of a large water basin
• High tech water technical area with various water silos for daily storage and modern water mixing and irrigation units
• Possibility to increase the company up to 2 x 9 ha, which means double surface
• Unique design of the office building
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7. Concept idea
The first step in the process was to
develop a lay out plus energy concept
and closed water circulation system.
For international projects this is usually
combined with a feasibility report plus
cost price calculation of the whole
operation.
We incorporate local climate and
circumstances, availability of water,
availability of energy and growing skills of
the staff and labourers.
Our goal is to develop the most efficient
and economic greenhouse in the given
circumstances.
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8. Detail design and engineering
After the conceptual phase has been approved
and frozen, we evaluate the project into the next
phase of detail design / engineering. In this stage
we work out all the technical installations in detail.
The whole list of technical installations, including
some specifics, is given on the next pages.
At the end of this stage we are able to conclude
all the information into a supply scope for the
hardware.
The whole design stage has been finished now
and we move towards procurement of all the
hardware and delivery to the customers’ building
site. Internationally, most components are
supplied by containers.
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9. General description of the project
General description of the whole project for 1 phase of 9 ha (22.5 acres) for a master plan of 18 ha (45 acres).
• Site development
• Greenhouse with 7m (21ft) gutter height and automatic roof cleaning devise
• Headhouse for logistics and packing with 2 loading docks
• Technical building for irrigation and heat and power.
• Irrigation system in a closed loop
• Rainwater harvesting pond of 22.440 m3 (approx. 800,000 cu-ft)
• Hot water boiler system and heat storage tank
• Screening installation
• Climate control computer
• CHP power generator of approx. 4,4 MW and phase 2 approx. 8,8 MW
• CO2 supply system for the plants
• Grow light installation.
• Cultivation system with hanging gutters
• Office building
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10. Site development
From grass to glass: - Ground works / leveling and filling
- GPS land measurements
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11. Greenhouse
Greenhouse with 7 m (21 ft) gutter height and automatic roof cleaning devise
Technical specifications
Type of greenhouse: 8,00 m (≈ 24 ft) Venlo-glasshouse (2 x 4,00 m bays ≈ 2 x 12 ft))
Greenhouse width: 80 bays à 4,00 m / 40 trellis girders à 8,00 m, length 275 m (≈ 900 ft)
2 bays à 4,00 m / 1 trellis girder à 8,70 m, length 175 m (≈ 575 ft)
Trust distance: 5,00 m (≈ 15 ft)
Gutter height: 7,00 m (≈ 21 ft) (ground level – underside of gutter)
Corridor: 8 m truss with 4,00 m Venlo bays as a free span
Technical area: various trusses with 4,00 m Venlo bays as a free span
Total surfaces: 90.392,50 m² (≈ 22.5 acres) (distance ctc greenhouse)
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12. Greenhouse
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13. Greenhouse
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14. Greenhouse
Corridor
Roof cleaning devise
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15. Greenhouse
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16. Headhouse
Headhouse for logistics and packing with 2 loading docks
Technical specifications
Type of headhouse: 28,00 m (≈ 92 ft) A-frame construction
Headhouse length: 47,00 m (≈ 154 ft)
Gutter height: 7,00 m (≈ 21 ft) (ground level – underside of gutter)
Surface: approx. 1.300 m² (≈ 14,000 sq-ft) packing building
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17. Technical building
Technical building for irrigation and heat and power
Technical specifications
Technical area: various trusses with 4,00 m (≈ 12 ft) Venlo bays as a free span
Surface: 2.380 m² (≈ 25,600 sq-ft) (distance ctc technical area)
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18. Technical building
Irrigation system in a closed loop
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19. Technical building
Water technical installation
Technical specifications for 9 ha (≈ 22.5 acres)
Fertilizer unit (liquid & solid fertilizer) 90 m3/hr (≈ 24,000 gallons/hr)
Drip pump unit 2x 90 m3/hr (≈ 2 x 24,000 gallons/hr)
UV-desinfection unit 15 m3/hr (≈ 4,000 gallons/hr)
RO unit 150 m3/day (≈ 40,000 gallons/day)
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20. Technical building
Lubron condensation water treatment
The objective of this installation is to purify approx. 600
liter/hour (≈ 160 gallons/hr) condensation water from the
CHP system with a natural gas use of 1.100 m3/hour (≈
39.000 gallons/hr) + condensation water of the CO2
installation of approx. 400 liter/hour. By purifying this
water, it can be reused as an addition to the rainwater.
Technical specifications
Type 1 x CW 1000
Capacity 500-1.000 liter/hour
(≈ 130-260 gallons/hr)
Water temperature 5 - 40°C (≈ 41-104°F)
Electrical connection 230 V, 50 Hz
Power 1x 0,5 kW
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21. Rain water harvesting pond
Year round water storage by means of a large rain water harvesting pond
Technical specifications
Surface: 12.500 m2 (≈ 3.10 acres)
Bank height: 2.90 m (≈ 9 ft)
Contents: 22.440 m 3
(≈ 791,000 cu-ft)
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22. Heating system
Hot water boiler system
Technical specifications
Capacity: 7 MW ≈ 24 MBTU/hr
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23. Heating system
Pipe heating
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24. Heating system
Heat storage tank
Technical specifications
Contents: 7.383 m3 (≈ 260,000 cu-ft)
Diameter: 28.000 mm (≈ 91 ft)
Height: 14.729 mm (≈ 48.5 ft)
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25. Climate control computer
Technical specifications
The climate computer controls all processes in and around the greenhouse:
Greenhouse Climate Control Irrigation
• Meteo station • Rain water storage
• 8 climate zones • Steering fertilizer unit
• Ventilation control • Drip irrigation system
• Energy saving screen • Steering UV disinfection unit
• Heating control
• CO2 dosing Management information
• Grow light steering • Graphical user interface
• Process dashboards
Energy • Historical graphs and tables
• Boiler room
• Hot water gas boiler
• CHP unit
• Heat storage
• Distributor with mixing groups
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26. Climate control computer
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27. CO2 supply system for the plants
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28. CHP power generator of approx. 4,4 MW
Technical specifications
Engine type (equipment)
Electrical capacity per engine: 4397 kW
Thermal capacity per engine: 4589 kW
Speed: 50 Hz
Voltage: 10.500 V
The installation includes:
• Gas system
• Outlet system
• Condenser
• Oil system
• CH system
• Electrical installation
• Flue gas cleaner
• Acoustic housing
• CodiNOx Exhaust gas purifier Acoustic housing
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29. CHP power generator of approx. 4,4 MW
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30. CHP power generator of approx. 4,4 MW
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31. Screening installation
Unique screening installation (Smartscreen)
Energy screening installations, light reduction installations and roller side screens
Technical specifications
Double screening installation:
Screening installation in open position
- Light reduction (XLS SL 99 W/W Revolux)
Screening percentage 99,5%
Energy saving 50%
- Energy saving (XLS 10 H2No Revolux)
Screening percentage 13%
Energy saving 47%
Screening installation in closed position
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32. Screening installation
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33. Screening installation
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34. Grow light installation
Technical specifications
Light intensity: ± 15.000 lux ≈ 215 µMol/m².s
Number of fittings : 11.552 HSE NXT 1000 Watt / 400 Volt electric with Beta reflector
Light: 11.552 Greenpower lights 1000 Watt El. 400 V.
Power in kVA: 12.326
1000 Watt / 400 V kW – 1,035
kVA – 1,067
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35. Cultivation system with hanging gutters
Technical specifications cultivation gutters
Width gutter 210 mm (≈ 8.25 inch)
Height gutter 120 mm (≈ 4.75 inch)
Depth water canals 60 mm (≈ 2.40 inch)
Width water canals 30 mm (≈ 1.20 inch)
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36. Cultivation system with hanging gutters
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37. Post Harvest installation
With an electric tow truck, the harvesting carts go Unloading the carts with the filled harvesting crates
transported automatically from greenhouse to the and loading the carts with empty crates.
packing building.
De-stacking the crates. Moving the crates to the stacking unit and
palletiser for transport.
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38. Contact information
VEK Adviesgroep B.V.
Jupiter 433, NL-2675 LX Honselersdijk
P.O. Box, NL-2675 ZW Honselersdijk
Phone +31 174 389666
Fax +31 174 389667
E-mail info@vek.nl
www.vek.nl
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