Sustainable Adapted Year-Round Production of Chemical-Free Strawberries

2004 Annual Report for FNC03-466

Project Type: Farmer/Rancher
Funds awarded in 2003: $5,600.00
Projected End Date: 12/31/2005
Matching Non-Federal Funds: $14,525.00
Region: North Central
State: Ohio
Project Coordinator:

Sustainable Adapted Year-Round Production of Chemical-Free Strawberries

Summary

PROJECT BACKGROUND
Bramble Creek Farms is a family-owned 45-acre farm along U.S. Route 50 and Collins Road in western Washington County, southeastern Ohio. Since its inception, Bramble Creek Farms has operated without use of chemicals. When purchased by Mike Neeley and Jackie LeBerth in 2001, the farm had been untended and unused for nearly 30 years, except for sporadic, unplanned removal of some oak, cherry, and poplar trees.

The first 10-acre field of blackberries and raspberries was put into production in fall 2000 (prior to actual purchase) with planting of 30 ‘Chester’ blackberry plants and 30 ‘Heritage’ black raspberry plants. Plants were transplants from a neighboring organic farm placed in raised beds, covered by landscaping fabric and cypress wood mulch. The following spring (2001), trellising and irrigation were added. A two-story, solar powered barn that now houses two horses, two goats (in winter) and some farm equipment was built that spring, along with a work shed constructed from rough cut, native cherry lumber. This year’s harvest marks the third, and most bountiful, of outdoor brambles.

Producing strawberries was a natural “fit” with bramble production, offering a comprehensive fruit offering to the buying public and expanding the farm selling season. Physical challenges for the two aging farmers in planting and harvesting gave rise to an adapted outdoor growing system. In spring-summer 2003, strawberries were planted in the blackberry-raspberry field in wooden boxes filled with sterilized potting soil and composed horse manure on wooden posts 40 inches off the ground. A gravity-fed irrigation “soaker” hose was used when rain was sparse. A tent of landscaping fabric over each planter box shielded the plants from summer sun.

This system, allowing for easy planting, weeding, and harvesting without constant bending, was the “pilot” for the greenhouse-based, grant-funded project. It soon became apparent that this system might be useful year round to grow strawberries, and perhaps other fruits and vegetables.

PROJECT DESCRIPTION AND RESULTS
The goals of this project were two fold:
 Attempt to expand the growing season to multiple strawberry crops per year, continuing to utilize traditional “dirt” for a growing medium, and without use of chemicals.
 Determine if strawberries could be grown successfully in containers on raised work benches, diminishing physical strain.

Process: In the interest of economy, a 30 ft. x 100 ft. greenhouse was purchased at a farm auction. It was adapted and reconstructed on one of the few level, accessible spots at Bramble Creek Farms. Several of the poles supporting the greenhouse had been damaged by snow load the previous winter, so the reconstructed greenhouse measures 30’x 75’. Despite advice to the contrary, the original two-layer plastic covering was reinstalled and continues to be serviceable.

We set up the greenhouse, a 30 ft. by 75 ft. conventional system, in September-October, 2003. We found much wasted space on the outer perimeters of the greenhouse. To eliminate the diminished height and make more space usable for planting, the greenhouse was raised 32 inches by extending the metal frame posts (this also allowed for frame reinforcement). The bottom 32- inch span was enclosed with pressure treated ½-inch plywood. Vents, 16 inches by 28 inches, were cut in each plywood section, equipped with screening and constructed so they can be opened during summer months and replaced with a four-screw attachment system in the winter months. This vent system works well. We maintained crops throughout the summer, although daily watering was crucial and vent fans ran continuously on the hottest days. In the height of summer heat, no production was realized from the strawberry plants, and plant stress was obvious. Installation of a shade cover would have helped. We were not able to afford a shade cover for this past summer, but intended to purchase one for use in summer 2005. We also discussed installation of a natural-gas-powered cooling system, a problem solver we intend to continue to investigate.

The Bramble Creek Farms greenhouse is more than a quarter mile from the main road. The access to the greenhouse was originally a washed-out logging road and was in need of much work for everyday use. Grading, drainage and 20 tons of gravel were installed to make the site usable and accessible.

A water line, providing water through the Little Hocking Water Association, was available at some distance form the greenhouse location. It required considerable excavation with a rented backhoe to locate and reroute the water line to the greenhouse. Throughout the first nine months of the project (including all summer), all watering was done by hand. This fall, the drip irrigation system purchased with the greenhouse was reinstalled. This works much better, allowing monitoring of water amounts and saving time.

The original grant proposal supported the use of solar panels to provide power to the greenhouse. When the project was started, there was no utility supplied power available at the farm. All other buildings and fencing continue to be powered by solar panels. It was our intention to use solar to create electricity for heater blowers, ventilation fans, and lights. This was not an economically feasible choice and electric service was installed at the greenhouse during construction and continued to be used throughout the growing season. The cost of the solar system (equipment and installation) necessary to meet the needs of this project was excessive when weighed against production return. We have not abandoned the idea of using alternative energy sources and plan to continue to investigate its feasibility. Especially during the summer, power expense was nearly $50 a month. On a positive note, access to traditional power sources also opens up the option to sell generated power back to the utility company, if and when a solar or wind-powered system is installed.

Fuel for the heating system at the greenhouse is provided by a natural gas well on the farm. When we purchased the greenhouse, it included two 175,000 btu heaters that were equipped to use propane fuel. I have, in the past, converted propane to natural gas by drilling out the orifices to a larger size. However, gas directly from the well burns somewhat hotter than refined natural gas, and I could not get the heaters to work as needed. By mid-December, we could not achieve the temperature necessary to bring the strawberries to flower and bear fruit. We then purchased one new 75,000 btu heater, which was not sufficient, but kept daytime temperatures in the 60s and nighttime in the 40s. We had strawberries beginning to bloom by the first of January, and by mid February were eating the fruits of our labor. When outdoor temperatures became warmer in early March and combined with the output from the lone heater, production escalated. Our theory, for the most part, had proven correct. To have strawberries with outstanding flavor, texture and size with snow on the ground was a wonderful experience.

Something we wished to accomplish with this project was to address the issue of aging farmers, developing a system that would take strawberries out of a hand-and-knee production. We built raised plant tables 38 inches high and 60 foot long of rough-cut cherry available from the farm. These tables are 48 inches wide. This width accommodates three three-gallon containers of berries. Each row can hold up to 156 containers. Most containers have two plants (some three), so each row is likely to have at least 315 plants. This size greenhouse can hold four rows with plenty of access in between. Three rows are placed now in the Bramble Creek greenhouse, with the final row to be installed this winter.

In the early stages of this research, 55 gallon plastic barrels were used to hold plants. The barrels were cut horizontally, making a trough-like planting system that could be taken in and out of the greenhouse on a seasonal basis. The entrances into the greenhouse were not large enough to accommodate equipment to perform this task. These barrels filled with soil and plants proved to be too heavy to move manually. We are now using three-gallon plastic containers, with at least two plants per container. We tried this last winter and production as acceptable.

Over the course of spring-summer 2004, an additional 250 plants, mostly ever bearing ‘Ozark Beauties’, were added. ‘Ozark Beauties’ seem to be our best producers, although we intend to continue to investigate other varieties that are used by specialty, niche markets. The majority of the plants were purchased as rooted starts, although for the past five months runners from existing plants have been rooted and then transplanted into growing containers. We also have experimented with planting ‘Sparkle’, ‘Fort Laramie’, and ‘Cavendish’ varieties of strawberries. ‘Ozark Beauties’ (both single and ever bearing) and ‘Fort Laramie’ were strong, consistent producers with average to large sized berries. ‘Cavendish’ performed poorly, producing inconsistent, small berries. ‘Sparkle’ performed adequately, producing average-sized fruit.

The availability of rooted plant starts is a problem during the winter. Growers are not willing to ship to Ohio before March 15. This presents a serious problem for greenhouse producers looking to generate off-season crops, especially using new varieties (otherwise, they could use runners.) identifying a reliable, reputable source for plant starts is crucial to developing plant variety and meeting production goals.

One of the issues to be addressed in this project was sustainability. This meant we needed to find a method to mimic plant dormancy, naturally brought on by colder temperatures. With a goal of year round production, the dormancy or hardening off process must be accomplished by artificial means. We found very little definitive research on the necessity of this process and how to do it. The limited information accessed was highly technical and scientific and of little value to the common farmer, concentrating on everyday production issues. We used a 3-cubic foot (dormitory sized) refrigerator in our efforts to harden off plants. In the first round, we used 15 plants. We removed the plants from the pots, trimmed back the stem, leaves, and roots to two inches, wrapped them in newspaper and placed the package in the cooler at 50 degrees. Over the course of three weeks, the temperature was slowly reduced to 28 degrees and gradually brought back up to 50 degrees. The plants were returned to pots and placed back on plant stands. We lost all 15 plants. I believe this failure was due to lack of moisture. The plants seemed to be too dry.

We tried again, using the same process, but this time the plants and newspaper were soaked in water before placement in the cooler. We faired somewhat better: three plants survived. In the next round of hardening experimentation, we left the roots and stems on, soaked plants and newspaper and placed the package in the cooler; six plants survived. For the next round, we left the soil on the roots, used the same process for newspaper and plants and placed the package in the cooler, all 15 plants survived. The same process was repeated a second time, and again all 15 plants survived. This appears to be the most viable method. However, about 75 percent of the plants did not undergo this “hardening off” process and appear to be strong and healthy. It is possible the seasonal drop in nighttime lows to the 30s is sufficient to keep the life cycle intact.

It is now November 15 and we are having low nighttime lows of 30 degrees. The heat is not yet turned on, but I plan to do so on November 20. All plants are healthy and appear posed to begin the next cycle.

People: Support for this venture came from a variety of quarters.
Innovative Farmers of Ohio, Laura Ann Bergman, consistently highlighted our work in newsletters and a directory of members, during the annual conference and other meetings of members and collaborators.

John Ellerman, Christy Welch and Sandy Kuhn, OSU South Centers at Piketon, provided ongoing technical assistance on production and marketing issues.

Eric Barrett, Washington County extension agent, provided ongoing technical assistance on production issues, contact for marketing (ongoing) and press coverage of SARE award.

Geoff Greenfield, Third Sun Solar and Wind Power, provided advice and costing for the proposed solar system. His company continues to be part of our technical assistance team.

Wendy Hess, AceNET, assisted in development of a logo and label for value-added products from Bramble Creek Farms. Although she no longer works for the agency, she continues to be a strong supporter of local agriculture.

RESULTS/DISCUSSION
What we learned:
• Temperature control is essential in successfully moving strawberries through their life cycle. Drastic alteration higher or lower from an average of 70 degrees means production is slowed or completely stalled. At the right temperatures, berries rapidly produce a great tasting berry, even in a greenhouse environment.
• Set realistic goals. We started with a goal of four production “seasons” per year. This is too ambitious. Two or three is more realistic. It is much easier/more doable to create sufficient warmth than to create sufficient coolness, so a fall-winter-spring production cycle is most realistic and still creates market opportunities. Traditional outdoor strawberry producers in Ohio rarely have product before Memorial Day. Effectively using the greenhouse to monitor planting-flowering-ripening cycles means mid-winter “homegrown” berries and pre-season product are available for both the wholesale and consumer market.
• Systems are essential. Heat and cooling, power and water are all essential to the successful operation of a greenhouse. Installing these systems “as you go” creates stress and anxiety and frequently means production gets off schedule. Especially if you work off-farm jobs, anticipating the next need in the production cycle is difficult, if not impossible. Having all systems in place at or near the beginning allows you to concentrate on planting, growing, harvesting, and marketing product.
• Penny wise and pound foolish. Economy is one of several primary considerations at Bramble Creek Farms. While purchasing a used greenhouse (complete with two ancient heater and overhead irrigation) was the most affordable acquisition strategy possible, dismantling it, hauling it more than an hour home, adapting it and reconstructing it (including reinstalling used plastic) was an extremely time consuming process, that still cost money. Before embarking on a project such as this, weigh all the costs (including the opportunity costs.)
• It can, and does, work. You can grow strawberries in dirt, in Ohio, in the winter, without chemicals. We learned that. There are variables and considerations that can and do enhance or diminish your crop. In 2005, we plan to learn form our misjudgments and make necessary alterations. We also plant to try other varieties of strawberries and other kinds of berries – raspberries and blackberries, specifically – to enhance the product mix and marketing season. We’ve also dabbled with other products – greens, potatoes and tomatoes – and are investigating markets for these off-season.
• This is a growth opportunity for us personally and professionally. One of our ongoing goals is to create employment from our farm, replacing one FTE in our family’s income. This greenhouse project has convinced us that a livelihood is possible with the farm, given sufficient time, energy, and financial investment. Most important is to create markets for our farm products, and those of other local producers. This discussion has given rise to a new “offshoot” enterprise, a farm to commercial user brokerage company specializing in locally produced food available for purchase by restaurants, groceries and other institutions.
• Most importantly, patience and flexibility. These two crucial traits will serve any farmer well, and seem to be “hard wired” in those who choose to farm. If at first you don’t succeed, try it again, and again, and again. And, be willing, even enthusiastic, about asking lots of questions and trying new ways.

OUTREACH
Individual tours – Much of the outreach for this project was accomplished through individual tours and discussions. All guests at Bramble Creek Bed and Breakfast were invited to tour the greenhouse and discuss the results. Guests were enthusiastic about the results of the project – obviously enjoying the “fruits” of the labor as part of their breakfast. Visits by other existing and potential greenhouse producers included discussion of the research underway with SARE’s help.

Innovative Farmers of Ohio – During the group’s annual conference, information about the project was discussed in a workshop on marketing and with interested individuals during networking sessions. IFO continues to support the research through a description in the group’s statewide directory. Bramble Creek Farms was first to sign up for an on-farm tour/workshop on IFO’s 2005 schedule.

Website – At www.bramblecreekfarms.com details of the project, along with photos, are available for viewing, along with information on contacting the SARE program.

PROGRAM EVALUATION
While this certainly creates an administrative slow-down, allowing a longer time frame for study would be helpful. It took so much time during 2004 for us to get all systems in place, work through problems and learn from our mistakes, that definitive production results took a back seat. I would like to start the actual research cycle now.

Collaborators:

Jackie LeBerth

257 Old River Rd
Little Hocking, OH 45742
Office Phone: 7409890334