Starting a Successful Hydroponic Commercial Greenhouse: Comprehensive Guide

Introduction: This article is relevant to those involved in commercial greenhouse agriculture or people interested in pursuing hydroponic agriculture production using heavy-duty greenhouse structures such as PC sheets or glass greenhouses, and various internal hydroponic equipment.
If your focus is related to hydroponic greenhouses, we believe this article can assist you (excluding thin film greenhouse structures).

Looking for a hydroponic commercial greenhouse for sale, or an aeroponic greenhouse?
We understand that exploring various options and making wise decisions can be overwhelming for hydroponic greenhouses,
which is why our design and planning services are completely free.
Our top priority is to help you find the most suitable product for your needs while maintaining affordability.

Do You Really Need A Hydroponic Greenhouse?

Many people don’t seriously consider hydroponic greenhouses, often being driven by curiosity or impulse.
However, they are suitable for both small-scale personal farms and large-scale commercial production,
as well as for organizations such as research institutions.
If you’re interested in hydroponic planting, start small with a 100-300 square meter area for testing.
Before deciding to invest in a 3,000-5,000 square meter or larger hydroponic greenhouse for stable vegetable and fruit production,
consider if it aligns with your business goals.

How Much Does It Cost to Build A Commercial Greenhouse?

This is a common question with no simple answer.
The cost varies by country, region, greenhouse type, materials used, and labor costs.
In general, commercial hydroponic greenhouses are made up of two components:
The greenhouse structure and the hydroponic cultivation system.

If a greenhouse is quoted at $25 per square foot, then first of all, the size of the greenhouse may be small, about 100 sqm.
In addition to the most basic greenhouse equipment, it may also be equipped with a lot of expensive auxiliary equipment.
For example, heating equipment and energy systems may be installed in Switzerland, the Netherlands, and Canada.
This price is closer to the cost of hydroponic indoor farms in Japan and Korea.
In the United Arab Emirates, Iraq, Oman, etc., this price is enough to install industrial-grade seawater purification systems.

However, the size of the greenhouse, the degree of automation, and customization can all impact the overall cost.
Additionally, different countries have unique price biases based on factors such as heating and energy costs,
geographical restrictions, and water and electricity conservation requirements.
Ultimately, the cost of building a commercial greenhouse depends on several factors,
and it’s best to consult with a professional to get an accurate estimate.

Is Hydroponic Greenhouse Profitable?

Yes, greenhouse hydroponic farming can be profitable.
Countries with limited land resources, extreme weather conditions, reliance on imported food, or those that produce high-value fruits and vegetables,
such as Canada, the Philippines, the United Arab Emirates, New Zealand, Oman, South Korea, Spain, and Vietnam, have a high demand for hydroponic farms.
Investing in higher-end indoor vertical farms can also be profitable as they allow for agricultural cultivation and tissue culture.

Before starting a hydroponic cultivation project, it is essential to consider the necessary conditions for commercial cultivation.
Here are some questions to ask:

1. Do you have enough budget to support your hydroponic cultivation project?
   Starting a hydroponic farm requires more investment than a regular greenhouse.
   Are there any agricultural subsidies or discounts in your area?
   Do you need to take out loans or seek financing?
2. Is the location suitable for hydroponic cultivation?
   It should be based on demand, not just for the sake of being trendy.
3. Does the local government and policies support your hydroponic greenhouse project?
   You may need to apply for relevant permits, consult project completion conditions and restrictions, or obtain bank approval.
4. What kind of vegetables and fruits do you want to grow?
   What is the required production volume, and what is the local market price for these crops?
   Can you ensure enough profit?
   Determining the type and volume of crops can allow suppliers to provide accurate equipment type and quantity information, which is the basis for greenhouse pricing.
   You can calculate the ROI to help decide whether to invest in this project.
5. Do you have a stable sales channel?
   Profitable hydroponic greenhouses have stable supply and sales channels,
   which may include large supermarkets, regional supermarket suppliers, wholesalers, brand chain restaurants, or market partners.

What are The Disadvantages of A Commercial Hydroponic Greenhouse?

Commercial Greenhouses for Sale: Key Factors to Consider Before Buying

Undoubtedly, the construction of any hydroponic greenhouse is highly customized!
Costs vary based on factors such as scale, materials, and different planting equipment.
Additionally, the higher the degree of automation or intelligence desired, the higher the cost.

Therefore, before constructing a hydroponic greenhouse, it’s important to understand that customized requirements vary due to individual differences.
This includes considerations such as:

• Choosing the appropriate hydroponic system ( For example: NFT Growing System, Vertical Plant Tower Farming, Hydroponic Bucket, Rolling Benches, DWC Hydroponic System, and so on.)
• Configuring the greenhouse to maximize the advantages of hydroponics
• Ways to manage hydroponic growing

By understanding these factors, you can make informed decisions on how to build and operate a hydroponic greenhouse.
This can also help your commercial greenhouse supplier provide tailored solutions to meet your specific needs.

Factors to Consider When Choosing Greenhouse Structure and Materials

It is important to consider various factors when selecting the appropriate greenhouse structure and materials.
While the choice of materials is significant, it is not the only deciding factor.
Other considerations such as geographic location, climate, land availability, and planting plans also need to be taken into account.

Characteristics of Glass and PC Boards as Greenhouse Materials

Glass and PC boards are popular choices for commercial greenhouse materials. Glass is known for its high transparency and excellent insulation, allowing for an extended growing season.
It’s typically made of high-quality tempered glass with aluminum alloy frames, which provide durability and wind resistance.
Meanwhile, PC boards offer high toughness and corrosion resistance, making them cost-effective as they are less likely to be damaged during transportation.

Types of Glass Used in Commercial Greenhouses

Tempered or laminated glass is commonly used in commercial glass greenhouses.
Ordinary single-layer tempered glass is known for its high strength, impact resistance, and safety features, as it does not produce sharp fragments when broken.

Laminated glass comes in different types, including:

1. Double-layer glass: Composed of two layers of glass with a certain distance between them, double-layer glass reduces heat loss and is a great choice for cold climates.
2. Insulated glass: Similar to double-layer glass, insulated glass can have two or three layers with inert gas or vacuum filled in the interlayer, which offers better heat insulation and reduces heat loss more efficiently.

Key Characteristics of Polycarbonate Greenhouse

PC boards, or polycarbonate sheets, are lightweight plastic sheets made from polycarbonate material.
They are highly regarded for their strength, transparency, UV resistance, heat resistance, sound insulation, and shock resistance.

Hollow PC sheets are typically used in commercial greenhouses, with single, double, or triple-layer types being the most common.
While solid boards are usually used in smaller scale greenhouses such as home gardens or backyards.

For commercial greenhouses, both pure PC sheets and UV-coated PC sheets are commonly used.
UV-coated PC sheets are more expensive, with a cost increase of around 10% to 30%, but they have better aging resistance and durability.
UV radiation can damage plant cells, nucleic acids, and chlorophyll, which can hinder plant growth and yield.
By filtering out some UV radiation, UV coatings can protect plants and improve their growth quality and yield.

PC sheets themselves have good impact resistance, and with the protection of UV coatings, scratches and damage to the panel surface can be reduced, thus extending their lifespan.
Therefore, in some cases, using UV-coated PC boards can actually reduce overall costs by reducing the frequency of replacement and maintenance.

Structural Framework

The structural framework is a critical element in the construction of a commercial greenhouse.
Steel and aluminum alloy are the two most commonly used materials for greenhouse frameworks.

Steel is known for its high strength and stability, making it a popular choice for large commercial greenhouses.
However, steel requires rust prevention treatment to avoid corrosion caused by long-term use.
On the other hand, aluminum alloy is lighter, less prone to rust, and has lower maintenance costs.
However, due to its relatively lower strength, it is not recommended for large commercial greenhouses.

When choosing the framework material, the size and scale of the greenhouse should be taken into consideration, along with the local weather conditions and budget constraints.

Glass vs. Polycarbonate Greenhouses: How to Make the Right Choice?

Auxiliary Equipment for Commercial Greenhouses

Commercial greenhouses require various types of auxiliary equipment to ensure the optimal growth conditions for plants.

These include heating and cooling systems, ventilation systems, lighting systems, irrigation systems, humidity control systems, shading systems, air circulation systems, and pest control equipment.
The selection of auxiliary equipment should be based on the specific needs of the crops being grown, the size and layout of the greenhouse, and the environmental conditions in the area.

By choosing the right equipment and systems, greenhouse operators can improve crop yields, reduce energy consumption, and enhance overall efficiency.

VENTILATION SYSTEM:

The ventilation system is essential for regulating temperature, humidity, and air quality by circulating air.
There are two main types of ventilation:
The natural and mechanical.

Natural ventilation is achieved by opening windows, while mechanical ventilation uses fans, wet curtains, and air treatment equipment.
When selecting fans, it’s important to ensure sufficient ventilation while also considering noise levels and energy consumption.
Opting for efficient and low-noise fans is recommended.

SHADING SYSTEM:

Shading equipment is essential for controlling indoor light intensity.
The primary function of shading curtains is to block excessive UV rays from the sun, which can cause the temperature to rise rapidly.

External, internal, or both types of shading systems can be installed.
Shading curtains not only prevent excessive light and high temperatures but also provide insulation in colder regions.
Automated shading systems can open and close curtains automatically according to the intensity of sunlight.

IRRIGATION SYSTEM:

The two most commonly used irrigation systems in hydroponic greenhouses are substrate nutrient solution machines and hydroponic water and nutrient solution machines.

The former is used for substrate cultivation of crops such as tomatoes, peppers, eggplants, cucumbers, and strawberries, and often employs drip irrigation.
The latter is used for leafy vegetables like lettuce, basil, cabbage, celery, and fog culture plants like potatoes and sweet potatoes.
Both systems provide crops with sufficient water and nutrients while saving water effectively, reducing water consumption by over 80% compared to ordinary greenhouse irrigation.
Different plants may require different irrigation systems or timed irrigation to adapt to varying growth stages.
The biggest difference between the two systems is that the substrate nutrient solution machine does not require return water.

CO2 SUPPLY SYSTEM:

A CO2 supply system, also known as gas fertilizer, is essential for commercial greenhouses to provide sufficient carbon dioxide for plant growth and yield.
CO2 shortage is a significant limiting factor for greenhouse cultivation.

This system is typically used as a supplement when there is weak light, high humidity, or slow airflow inside the greenhouse, and CO2 cannot be easily replenished from the atmosphere.
Increasing ventilation can usually solve this problem, but it may not be effective during cold weather when the greenhouse is tightly sealed.
In hydroponic cultivation, releasing CO2 can be challenging since it lacks soil and organic fertilizer.
Therefore, installing a CO2 supply system is particularly necessary for indoor cultivation.

MONITORING SYSTEM:

Real-time monitoring of environmental parameters, such as temperature, humidity, and CO2 concentration, is crucial in commercial greenhouses for timely adjustment of the greenhouse environment.
Monitoring systems can help you understand and adjust indoor environments in real-time to improve crop growth efficiency and quality.
Additionally, they can monitor the outside environment, provide feedback to the control center in a timely manner, and protect the greenhouse from external damage.

We can list some commonly used monitoring options:

• Indoor environment monitoring:
  indoor temperature, humidity, CO2 concentration, and light intensity.
• Outdoor meteorological station monitoring:
  wind speed, wind direction, rain and snow, temperature, humidity, light intensity, CO2, oxygen, air pressure, and radiation, etc.
• Planting environment monitoring:
  soil matrix or nutrient solution pH, temperature, humidity, ECPH, liquid temperature, etc.
  By collecting real-time data, wirelessly transmitting, and remotely controlling, the monitoring system can automatically control the humidity curtain fan, internal and external shading, roof window side window, heating and lighting equipment, drip irrigation, and sprinkler, including equipment operating time, interval times, and work frequency, to create suitable planting environments for different growth stages of crops in the greenhouse.

SOLAR POWER SYSTEM:

A solar power system includes solar panels, batteries, inverters, controllers, and other components, and can operate in two modes: grid-tied and off-grid.
To connect to the national power grid, you must consult relevant departments to determine the maximum allowable power consumption, regulations for connection, and the need for power reserve applications.
When considering off-grid power supply, it is essential to calculate the return on investment and consider the battery capacity and lifespan to avoid losses.

HEATING SYSTEM:

In cold winter or low-temperature areas, commercial greenhouses need suitable temperature to ensure crop growth, so heating systems are essential.
Common heating systems include electric, gas, and solar heating equipment, which can use hot water circulation, hot air circulation, and ground heating.
It is recommended to use heating equipment with a temperature controller for precise temperature control.
Ground heating systems require careful calculation of ground thermal conductivity and heat loss.

CONTROL SYSTEM:

The PLC power control cabinet is a crucial component of the control system, as it allows for the automation of various greenhouse systems.
It is a customizable, programmable control kit that can control motors and switches locally or remotely.
With an independent control panel and the use of PLC technology, it can determine power supply and data transmission lines based on the size of the greenhouse.
By connecting various systems such as ventilation, shading, irrigation, CO2 supply, environmental monitoring, solar, heating systems, as well as pumps and valves, to the PLC control cabinet, all processes can be automated, including remote monitoring and control at any time.

The above equipment are commonly used in commercial greenhouses as auxiliary tools.
However, the specific combination and usage of equipment depend on the particular application scenarios and requirements.
To learn more about hydroponic or aeroponic systems used in hydroponic greenhouses, click here.

Effective Communication with Commercial Greenhouse Suppliers for Procurement

Through our communication with many clients, we have observed that each client has slightly different focuses.
However, only a few provide detailed and accurate information that helps us solve problems and provide suitable solutions.

While we understand that many people want to know the project cost urgently, this can decrease communication efficiency and prevent a comprehensive understanding of the project composition and principles, which can be unfavorable in the long run. Overly simplified information can also lead to a lack of customization and increase overall costs.

For instance, many commercial clients who do not own farms have extensive demands and list various crops for a quotation.
In such cases, we can only recommend the best equipment options rather than the most suitable ones, which can result in a cost estimate that is higher than actual costs.
This highlights the importance of a well-planned project.

How to Effectively Communicate With Greenhouse Suppliers for Procurement?

If you want to establish a commercial hydroponic greenhouse quickly but don’t know where to start, the best way is to communicate with your supplier about the input-output ratio and yield.

Why? No matter what your purpose is – personal use, production and sales, experimental research – it ultimately cannot be separated from the goals of input and revenue.

• What is the upper limit of the cost of establishing a greenhouse?
• How many years do you plan to recoup your costs and start making a profit?
• How much yield do you need to achieve this goal?
• These are the starting points for the key issues you should focus on, and they can guide you towards a series of results regarding prices, equipment information, and technical means.

Once you have a clear understanding of your purpose and needs, how can you effectively communicate with your supplier?
If you are looking to purchase hydroponic greenhouse equipment from China, you can follow these steps to communicate with the supplier about procurement matters:

I. Determine Hydroponics Greenhouse Needs

First, confirm your specific needs.

• What type of greenhouse do you require?
• What is the scale of your operation?
• Do you need just a greenhouse, or do you also require a hydroponic system?
• What crops do you plan to grow and why?

Understanding the “why” behind your choices is crucial as it helps you assess whether there is local demand for the produce, the market price, wholesale and retail prices, and the yield required to meet your profit expectations.

Considerations for your actual environment or personal preferences should also be taken into account.
For instance,

• If there is a water shortage, do you require a water-saving planting system or a seawater purification device?
• Is automation necessary to reduce labor costs?
• Does the establishment of the greenhouse system require the addition of solar or other energy supply equipment?
• Is local installation service available?

II. Introduce Your Farm

When communicating with your supplier, it’s important to provide information about your farm, including the size, production requirements, and climate conditions.
This information should include the types of crops being grown, the greenhouse area, expected yield, and the highest and lowest temperatures throughout the year, as well as average temperature, wind speed, and desired greenhouse materials.

By understanding these specifics, the supplier can offer suitable solutions and provide you with a quick quote.
Here’s why each piece of information is important:

FARM SIZE – Greenhouse area is necessary for designing the greenhouse and laying out internal equipment.

TYPES OF CROPS AND PRODUCTION REQUIREMENTS – Yield requirements can change the style of the cultivation system or greenhouse space, such as increasing the height of vertical equipment or customizing systems to increase production frequency. Knowing the type of crop can also determine the type of cultivation system and related auxiliary equipment needed.

CLIMATE CONDITIONS – This includes temperature, wind speed, weather conditions, and geographic location. Environmental factors determine the materials used for the greenhouse, such as the thickness of the board, height, span, and openings, as well as the number of fans and shading system styles needed.

III, Obtain Greenhouse Design and Quotation

With the information you’ve provided, the supplier can design the greenhouse floor plan, layout for auxiliary equipment, and provide a detailed and valuable quotation.

While the quotation may not be final, it can help you plan the commercial greenhouse system, evaluate the budget and production volume to see if they meet your expectations, and serve as a comprehensive and valuable reference point.

IV, Abandon or Optimize the Greenhouse Project

At this stage, you should have a general idea of whether establishing your own hydroponic commercial greenhouse is feasible.

If the cost is too high, or the greenhouse design does not meet your requirements, or if the supplier’s services are inadequate, you can seek advice from other suppliers or choose to abandon the project.
Your decision to do so will also benefit the supplier by saving them the cost of further ineffective communication.

If the price is within your budget, or if there is room for negotiation, you can further refine the details of the greenhouse design.
Regardless of whether you decide to proceed with the project, adopting this communication method can significantly reduce the time and cost for both parties and improve communication efficiency.

What Information is Often Overlooked?

1. Installation and After-sales Service:

It’s important to ask the supplier about installation and after-sales services, including system installation, debugging, training, and maintenance to ensure the proper operation and maintenance of the system.

2. Policy Restrictions:

Some countries have import restrictions, tariffs, quality standards, and other requirements that should be considered to avoid purchasing problems due to policy issues.

3. Local Government Regulations and Guidelines:

Consult with relevant local departments to understand the restrictions on greenhouse water and electricity supply, available agricultural subsidies, and the necessary greenhouse permits.
If you plan to increase solar energy equipment, make sure to check if the local area can supply electricity or if you need to choose an off-grid system.

4. Do You Need to Grow Seedlings Yourself or Buy Them?

This is a commonly overlooked question.

• Leafy vegetables are relatively easy to grow, and vertical seedling systems can be used.
• Fruit and vegetable crops like peppers, tomatoes, and cucumbers are also not delicate and can be grown easily, so growing seedlings yourself is not a problem.
• However, crops like strawberries require some agricultural skills, and eggplants require grafting, which has a certain learning curve.

Moreover, these seedlings’ equipment also take up a portion of the planting area of the greenhouse. It is a question worth considering.

Lastly, if you’re interested in establishing your own greenhouse system, consider starting with our professional customized plan for hydroponic commercial greenhouses. We offer individual customized greenhouses for sale, individual customized hydroponic systems for sale, or even turnkey projects with local installation. Contact us now to discuss your options or take a look at our hydroponic or aeroponic greenhouse systems first.