Second Skin renovation Porta Nova in Waddinxveen

The first few days of the project in the greenhouse at rose grower Porta Nova in Waddinxveen “took some searching”. “The material is a bit different from steel,” Luke knows. “In the end it all went smoothly. We were able to do 14 km a day. That’s at least as fast as steel and even a tad faster.”

On existing system
For Metazet, this was the first major field project with the innovation presented last summer. “We did already have Second Skin on a dozen projects on a smaller scale. In each case, this involved one and a half to two kilometers of gutters.”

At Porta Nova, the pressure was on more. “As soon as the plants come, you have to be ready. In rose growing, the plants are on the gutter for years. With that, you have one chance to get it right for about eight years.”

In Waddinxveen, the Gutters in 4.3 acres of greenhouse were in need of renewal. “Here we placed Second Skin on top of the existing system with existing gutters. The existing gutters were used as a carrier and a completely new plastic top layer went on top.”

Labor and hygiene advantage
The renovation job required fewer people than normal for steel Gutters. “Normally you have one man at every two columns. That means about fifteen men per cap. On this project, we were able to move the guides with three men and do the walking out with the wheel set. The weight of plastic is lower and the fact that we can use the existing gutter as a guide also helps tremendously.”

In new construction with Second Skin, the labor advantage falls away. “In that case, we roll the steel supports and pull the plastic top layer directly over them.” What remains for both renovation and new construction are the other benefits of the innovation. “With this product, we help growers improve hygiene in the greenhouse. The material is smoother than steel. Artificial residues, algae and dirt adhere much less to the plastic second skin. Second Skin also stands up well to the increasingly intensive cleaning and disinfection of greenhouses. It gives growers flexibility in their choice of agents.”

Lower costs in the long run
Until now, Metazet gained practical experience in crops where the existing gutter construction remained during renovation. Unlike replacing steel gutters, you don’t demolish the entire structure from the greenhouse. “The steel structure on which the gutters stand will last the entire life of the greenhouse. With Second Skin, you only have to replace the top layer.”

A greenhouse easily lives to be thirty years or even older these days, Luke knows. “So if you build new and use Second Skin, you invest once in the gutter construction and later you only have to replace the top layer. The plastic top layer technically lasts 10 to 12 years, and maybe even longer. At the bottom line, with Second Skin, you are cheaper for the entire life of your cultivation system. With Second Skin, you put in plastic for less than half the price of a steel gutter.”

Crop rotation
Now that the first major field project is over, Metazet can start putting in mileage later this year. “For us, it was convenient that this project was relatively close to home. We were able to fine-tune the forming technique and the new machines for Second Skin and completed the project on schedule. For us the ideal warm-up for the projects to come.” The first major project in fruiting vegetables will follow this summer, with many more projects on the horizon by the time of the crop rotation. “The technology has matured at lightning speed.”