From expanding product offerings to upgrading their growing media and heating, this third-gen greenhouse operation is still trying new tricks.

Founded in 1951 by Robert Cuthbert, third-generation family-owned Cuthbert Greenhouse is located in Groveport, Ohio — just a 20-minute drive from the convention center where Cultivate'22 is happening in Columbus. What began as a starter plant supplier has now become a 26-acre operation run by his grandsons David, Brett and Greg. 

With 12 acres under cover and 14 acres outdoors, Cuthbert grows a diverse selection of crops that includes mums, annuals and poinsettias, among others. Their customer base is as diverse as their offerings and includes produce stores in the Columbus area, Kroger, Costco, florists and landscapers. David said maintaining such a diverse customer base is important, as they don’t want any single customer to make up more than 35% of their business.

Cuthbert still uses many of the original structures from the 1950s. While leading one of the two tour groups through the operation, David remarked how he works in the same buildings today as he did when he was a teenager. Of course, there’s always a need for upkeep, and David said the team is planning to replace a couple of old houses. David pointed out one of those houses on the tour, which had collapsed in February after a lot of rain turned into ice and became too heavy for the house.

Though many of the buildings remain the same, David explained that Cuthbert recently made a big change when, after trialing it for a year, they decided to incorporate HydraFiber into their mixes. Most of their mixes consist of about 30% HydraFiber, though they often vary the composition based on what they’re growing.

Another upgrade they’re planning to make soon is in heating, with the goal of being more energy efficient. David said the operation currently uses several different heating systems, including steam heat, wood, a boiler and gas. Since heating is one of their biggest expenses, it’s crucial to become more efficient and save where they can.

One aspect that's been a challenge for Cuthbert is materials. Most of their big pots come from China, so port closures and shipping issues have delayed expected shipments. David, however, pointed out that domestically produced materials have also become hard to acquire, with some suppliers telling the operation to order at least a year in advance. David said they’re currently ordering their spring materials plus an extra 10% just to be safe.

Editor's note: Cuthbert Greenhouse was part of the greenhouse production tour at Cutlivate'22.

Owner Dan VanWingerden founded the business in January 2020.

Dan VanWingerden, the 26-year-old owner and founder of Green Legacy, has a clear plan for the business. 

Founded in January 2020, Green Legacy is located in Orient, Ohio — a 20-minute drive from Columbus. The greenhouses themselves are facilities VanWingerden purchased from the owners of Cuthbert Greenhouse, another Columbus-area business. 

What VanWingerden and his team have done since starting the business is mold it to make it the way they want it. They’ve also approached that by taking the facility they purchased from Cuthbert and improving the existing structure and bringing in their own equipment. 

They’ve reorganized much of the facility, moving machinery, work stations and growing spaces around so they flow in a more circular fashion. The idea, VanWingerden said while guiding the tour, is to be as efficient as possible. Every room and every space has a purpose. 

One way they’ve worked to improve efficiency is by largely growing product — during the tour, production was a mix of potted annuals and mums — on the floor vs. on benches. According to VanWingerden, the choice to not grow on tables creates more space for various plants and increases growing capacity by roughly 35%. 

There are clear plans to build out the business as well. For starters, VanWingerden has plans to add a pond or another well to the property to increase the amount of water available. This is necessary, he said, because they don't have access to city water on the site. They also plan to install a water tank to allow the water to be treated before it’s run through greenhouse pipes. 

They also have plans to evolve their customer base. Year one was 100% contract growing for other VanWingerden-owned businesses. (He previously worked at ColorPoint in Kentucky under his father, and his extended family all work in the greenhouse industry. They are, in fact, those VanWingerdens.) Year two saw the company target independent garden centers and landscapers; those two groups combined to account for 25% of the company’s business that year. Next year, VanWingerden said, the goal is to bump that figure up to roughly 40%. 

One other topic VanWingerden touched on was labor. The first year, he said, they had to rely on a temp agency to hire employees. This year, however, word of mouth in the community meant they did not have to hire a temp agency to fill open positions. In the future, VanWingerden said they will look into H-2A workers as the company gets bigger and more labor is needed. 

At Cultivate'22, Jonathan Pedersen shared Monrovia's approach to automation.

On Saturday, July 16, Jonathan Pedersen, CEO of Monrovia, spoke to a standing-room-only crowd at Cultivate’22 about how the nursery has implemented automation.

Monrovia has growing facilities at its Azusa, California headquarters, as well as Visalia, California, Dayton, Oregon, Granby, Connecticut, and Cairo, Georgia. Monrovia grows a wide variety of plants across those locations (more than 4,000), which makes automation more difficult. Many machines aren’t flexible enough to do what they do for different sizes or types of plants, Pedersen observes. To complicate matters further, much of today’s automation equipment comes from Europe, where the size and scale of nurseries is not the same as in the U.S., he adds.

So before investing a ton of time and resources into automation equipment, Monrovia analyzes if it will be worth it.

“If you can’t measure it, maybe you shouldn’t be doing it,” Pedersen said. “If you can’t measure the return, why are you spending the money?”

Like growing plants, trialing and testing is a big part of Monrovia’s approach to automation. A data-driven approach is crucial to this. There are many tasks you can automate, Pedersen said, but you have to decide which ones will be worth the investment.

“We want to keep our craftsmen on tasks where they add value,” he said, “not bent over spacing plants. Is the job best for a human to do? If not, how can we automate it?”

Define the process, measure it, analyze, improve, then control. Every step is critical, but Pedersen said the control is the hardest because it’s difficult to fight inertia.

“Human nature is to go back to what you know, and quite often we’ll update a process, we’ll prove it’s a better process and more efficient, but if you don’t stick with it, people’s habits will go back to what they were,” he said.

Before you get started with automation, you should find or develop a ROI model to measure your return on investment. Monrovia has a simple one that helps with project prioritization.

Here's the formula Monrovia uses: ROI = [(Financial value – project cost) / Project cost] x 100

Year 3 is most often the time when the project breaks even and pays for itself, Pedersen said. Other important questions to ask: Can you measure the results and effect on the business? Will it require other process changes either up or down stream? If it does, how much?

Also, be realistic about the time and resources necessary to implement the automation you’re considering.

“It isn’t just money,” Pedersen said.

He suggests doubling your original estimate of how long it will take to get the new process running smoothly.

Monrovia almost always makes adjustments to the equipment once it’s working in the fields. One particular change that Pedersen said is hugely beneficial is adding hour meters to machines to determine how much they’re being used. This helps measure if a new machine is providing the ROI they hoped it would.

One of the most important lessons learned from automation at Monrovia is that it’s important for your employees to the “why” behind automation, not just the “how.” They need to feel comfortable with the equipment and understand that you’re improving their jobs, not eliminating them.

“If they think they’re being replaced, they’re not going to want to use your shiny new equipment,” Pedersen said.

Start with some easy projects to get a few wins under your belt. Your employees will start to buy in, and hopefully they will become a source of new automation ideas. Expect some failures, as well. Sometimes you’ll buy an expensive piece of equipment and end up parking it in a field for a year while you figure out how to make it work with your existing operation. But Pedersen implores growers to not give up when you experience a setback. Automation done well can improve plant quality through uniformity and make worker’s jobs better by minimizing repetitive strain injuries.

Direct sales of BotaniGard will be available for garden, greenhouse and nursery use starting Oct. 1.

Certis Biologicals, the manufacturer of BotaniGard and Mycotrol mycoinsecticides, will begin sales of its products to established nursery and greenhouse pesticide distributors on Oct. 1, 2022. The company had distributed the two products through a third party under an agreement that ends in September. Certis Biologicals will begin selling the bioinsecticide products directly through their established distribution channel partners.  

“BotaniGard and Mycotrol are proven and highly effective products powered by Beauveria bassiana strain GHA. We are grateful for the opportunity to supply these products to the customers who have depended upon them to protect plants in their greenhouses, nurseries and gardens for years,” said Amy O’Shea, president and CEO. “We will be using the weight of our established distribution channel partners and experienced technical staff to support the transition of these products back into our portfolio.” 

Beginning Oct. 1, customers will be able to purchase BOTANIGARD 22WP, BOTANIGARD ES, BOTANIGARD MAXX, MYCOTROL WPO and MYCOTROL ESO from Certis Biologicals through leading retailers and distributors. BotaniGard and Mycotrol products are manufactured by Certis Biologicals in their US-based manufacturing facilities using the GHA strain of Beauveria bassiana. They provide control against all life cycle stages of aphids, thrips, weevils, whiteflies and many other insects that threaten the health and yields of crops. 

“Certis Biologicals has long been the leader in providing solutions for all growers, whether they are large-scale commercial producers who grow in-ground or in greenhouses or gardeners in their own backyards,” says Jim Black, business director. “Our successful partnership with BioWorks will continue as we work together to successfully transition customers of BotaniGard and Mycotrol to Certis Biologicals.” 

Certis Biologicals and BioWorks are collaborating to ensure that all customers are served during this summer and into early fall. Customers who are interested in learning more about Certis Biologicals can visit www.certisbio.com or www.certisbio.com/greenhouse.  

Stop by booth #1637 to pick up the latest issues of Greenhouse Management, Nursery Management, Garden Center magazine and more.

Heading to Cultivate’22? Then be sure to stop by the GIE Media booth, #1637.

At the GIE Media booth, the latest issues of market-leading publications — including Greenhouse Management, Nursery Management and Garden Center magazine — will be available. You can also claim your FREE subscription to any of the magazines at our booth.

Additionally, learn more about two upcoming GIE Media events: the Garden Center Conference & Expo and the Nursery Management Conference.

The former is scheduled for Aug. 1-3 in Orlando. The Garden Center Conference & Expo is an inspiration-packed, education-driven forum guaranteed to engage your mind and expand your relationships. Featuring an education track for executives and another tailored specifically for team leaders, it’s the one event designed with something for every individual in your operation.

It’s your opportunity to share experiences, find new products, connect with your community and create new partnerships. It’s time to come together to learn and grow as a team. Don’t miss your chance to hear from some of the best and brightest minds in the industry, reconnect with old friends and make some new ones.

Join us at the Garden Center Conference & Expo and let’s get growing! Rates increase on 7/29, so the time to register is now!

The latter, meanwhile, is scheduled for Sept. 26-28 in Forth Worth, Texas. The nursery management industry is filled with its own set of unique challenges. From labor to customer retention and succession planning to supply chain issues — the spectrum is vast. BUT YOU ARE NOT IN IT ALONE!

The Nursery Management Conference brings together industry peers who face the same challenges as you. They understand what keeps you up at night and they are coming to the Nursery Management Conference with candor, openness and the spirit of collaboration.

Join us in Fort Worth, Texas, Sept. 26-28, 2022 for next-level education and candid roundtable discussions. You will leave with tangible, actionable ideas that will improve production processes, bolster business management techniques and grow profits!

Rates increase in just over a week, to register today to secure your best rate.

Learn about each event, the full range of GIE Media products and meet members of the editorial and sales teams at booth #1637 at Cultivate’22! We hope to see you there.