Cutting Costs Without Cutting Corners

Pierre-Marc de Champlain

In today’s competitive greenhouse industry, the choices you make can significantly impact your bottom line. Before considering cutting costs in growing media, it’s crucial to evaluate the unit price in relation to its volume. The correlation between the pricing of compressed growing media and its final usable volume will reveal much about the overall value proposition. Here's how to read between the lines:

1. Compression ratio and usable volume

Expansion factor: Compressed peat-based products are designed to expand when fluffed, and with the addition of water, increase their volume significantly. This expansion factor will vary depending on the composition of the mix, the compression rate and the initial moisture content. If the growing media contains a lot of incompressible materials (i.e., bark, perlite, etc.), the compression rate and usable volume will be smaller. Good quality peat moss will swell and expand when hydrated. This is why proper rehydration is key to get the most out of compressed media. However, if the growing media already has a high initial moisture content (>55% to 60%), not only will its transport be more expensive, but you won’t get the volume expansion benefits after proper hydration.

True cost per volume: Instead of focusing solely on the price per compressed unit, calculate your cost per expanded volume (i.e., per cubic foot or liter). You can also compare the average number of containers you fill per unit. A product with a higher upfront price might result in more media once expanded, lowering the effective cost per unit of usable media.

2. Consistency and predictability

Reliable performance: Professional grade compressed media are engineered to provide uniform physical and chemical properties, offering predictable results. This consistency is crucial for professional growers who need reliability to respect their busy production and shipping schedules. While the upfront cost might be higher, the uniformity and predictability reduce the risk of crop losses and lower yields, therefore decrease the need for additional inputs or labor to correct issues.

The pricing of compressed professional growing media is closely tied to its final expanded volume and overall performance. Higher quality, compressed media often offer a better return on investment when you consider the true cost per unit of expanded volume, the quality of the ingredients and the efficiency in terms of handling, storage and yield. By focusing on the final usable volume and the performance of the media post-expansion, rather than just the unit price, you can better assess the overall value and cost-effectiveness of the product.

While cutting costs can be a strategy in some areas, skimping on the quality of your starting materials is a gamble that can backfire. Opting for lower-cost, lower-quality growing media might seem like a way to save money, but it can lead to more problems than it solves.

Inferior growing media can lead to numerous challenges that impact the efficiency and profitability of your greenhouse operation. Let us dive deeper and review some of the issues you may encounter.

Inconsistent growth: Inferior mixes can result in uneven water retention and variable composition, leading to unpredictable plant development. These inconsistencies can delay your production timelines, leaving you with fewer plants to sell or poorer-quality crops.

Longer production cycles: Poor-quality growing media can slow down root establishment and overall growth, which extends production cycles. This translates to higher labor and resource costs, as your crops take longer to reach maturity.  

Higher disease rates: Low-quality media can lack the proper water-to-air ratio necessary to support healthy plant growth, making plants more susceptible to diseases and/or pests. This can lead to increased fungicide or pesticide use and the potential for greater unsellable or lost crops.

More labor, more downtime: Lower-cost growing media often lack stringent quality control standards. As a result, these mixes may contain weeds, debris or other unwanted materials that can become a significant nuisance. This not only has the potential to increase the need for weed management, but can also lead to additional downtime on the potting line due to equipment jams or breakdowns.

How premium growing mixes save you money

After considering the various problems linked to lower quality growing media, it becomes evident that trying to cut costs on substrates can lead to numerous setbacks. Now, let’s explore how investing in a premium growing mix can actually save you money, time and give you peace of mind. Here are four key examples where premium mixes, like those from Berger, can deliver significant savings:

1. Faster, more uniform growth: High-end growing medias are designed to provide the ideal balance of air and water, promoting faster root development, and more consistent growth across your crops. This consistency allows you to maintain a reliable production schedule, and reduce labor and energy costs.

2. Faster crop cycles: Premium substrates foster faster plant establishment and healthier root systems, allowing for quicker turnover between crops. With more efficient growth, you can potentially increase the number of crop cycles per year, maximizing your greenhouse's productivity and revenue potential. This leads to more opportunities for harvests and profits within the same period, giving you a competitive edge.

3. Reduced input costs: Premium growing media can lead to significant savings by optimizing water and nutrient retention, which reduces the need for frequent watering and fertilization. This efficiency ensures that your plants make the most of the resources provided, leading to healthier growth with fewer inputs. Additionally, with stronger root systems and faster plant establishment, maintenance becomes less labor-intensive, decreasing the time and cost associated with frequent upkeep. In summary, by investing in high-quality media, you not only lower material expenses, but also save on labor costs, ultimately enhancing your overall profitability.

4. Lower disease risk: Premium mixes are formulated to promote strong, healthy plants that are more resistant to disease. By improving plant resilience, you may reduce the need for costly pesticides and other chemical treatments, keeping your crops safe and your wallet in your pocket.

In the competitive world of greenhouse production, the decisions you make about growing media can have a profound impact on your operation's efficiency, profitability and long-term success. While it might be tempting to cut costs by opting for lower-priced, lower-quality growing media, this approach often leads to hidden expenses in the form of inconsistent growth, longer production cycles and higher crop losses. These setbacks not only increase your operational costs, but also put your livelihood and reputation at risk.

Investing in premium growing mixes, on the other hand, offers a range of benefits that contribute to long-term savings. From faster, more uniform growth to reduced input costs and lower disease risk, high-quality growing media are designed to support healthier, more resilient plants. Moreover, a superior growing media manufacturer like Berger also offers complimentary analytical laboratory services, as well as equipment and grower support. By focusing on the true cost per unit of usable volume and the overall performance of the media, you can make informed decisions that protect your bottom line and enhance your greenhouse's productivity.

In the end, cutting corners on growing media is a gamble that can compromise your entire operation. By choosing premium mixes, you ensure that your plants receive the optimal environment for growth, leading to better yields, more efficient production cycles, and ultimately, a stronger, more profitable business.  

Pierre-Marc de Champlain is the director of technical services for Berger. He has a bachelor’s degree in Biotechnological Engineering from the University of Sherbrooke and has experience in water treatment, soil ecology research and food safety. Visit berger.ca for more information.