Innovation

Before Tunnel Vision Hoops, farming in city and urban areas in the mid-west proved to be particularly difficult because of inclement weather and unsuitable land conditions. Greenhouses have long been the most common solution for farmers because of their ability to offer greater control on climate conditions. Unfortunately, there were limited options for low-cost greenhouse structures that were able to withstand strong winds or heavy snowfall and an ability to be built in areas with cement ridden, rocky terrain.

Tunnel Vision Hoops' first innovation focused on how the base of their greenhouses would be fastened to the ground for a stronger foundation. Most greenhouses like hoop-houses and high-tunnels relied on building a foundation that relied on single posts to be driven into the ground. This design was limiting since it could not be built in tougher terrain and did not offer the strongest support against strong winds and heavy snowfalls. Their solution strayed away from the single ground-post anchoring design with the innovation of using shorter bi-directional cross anchors that acted like a tree root system.

Another later innovation that gave them outstanding recognition was their patented redesign of the end wall. This focused on a half-dome shape at either end that could fold upwards to allow for added utility and increased ventilation. The only comparable option that competitors were offering was a steel roll-up door. This was desirable for farmers to have easier access to their crop and be able to drive small tractor machinery into their unit. Tunnel Vision Hoops' solution provided similar benefits to the steel door and increased ventilation for pollination at a significantly lower cost.

These innovations not only improved the overall support of the structure but, for the first time, proved to last through the winter and allowed for year-round farming. Their innovation also opened up the opportunity to construct in areas that would not originally allow for single posts being driven deep into the ground. This opened up more feasible opportunities for growers to cultivate their crops in city and urban areas where rock, stone, sleet, wind, and snow were inhibiting. All the while remaining focused on providing these added benefits at low cost. Not to mention, in their six years of existence, they have yet to have any of their installed designs collapse or lift off the ground.

Inspiration

Todd and Carlton’s inspiration for their innovative design came from their shared passion of operating their own farms and growing their own food. The two met at a barn raising where a mutual friend was installing a hoop house structure that he purchased online. Todd even joked with Carlton about how they should reconsider their profession since they’ve become skilled in constructing the kit which offered limited instruction to something particularly difficult to construct. Once construction was complete it was only a matter of weeks until their friend called them back with concerns that his hoop house would blow over in a winter storm.

This motivated them to reconfigure a hoop house prototype of their own and in 2010 took to Sustainable Cleveland Summit to share their reinvented design with others. It was there that they realized the immediate demand that local farmers and growers had for their design. Todd and Carlton were not alone in their passion for growing their own food and were joined by others with a new found optimism of being able to grow in difficult conditions year round.

Todd, who majored in Sustainability and Environment Studies at Baldwin Wallace, mentioned "I never imagined I'd be constructing greenhouses as a profession but growing is something I am passionate about. I'm proud of the fact we are able to exist as a company where our contributions and innovations continue to create and discover new found demands. It would have been a lot easier to have quoted them (our clients) on what our competition was quoting but instead, we stood tough in providing offerings that have never collapsed or lifted off the ground. Six years later, holding the integrity of our structures has made us who we are."

Overall impact

The benefits that this provides to individuals and local businesses is endless. The ability to be able to grow year round has an immediate impact for growers to plant more food, make more money, and live a less stressful, more enjoyable life. It also created new opportunities for inexperienced growers to start their own farms in once unutilized land plots. Additionally, it provided local grocers, markets, and restaurants with the opportunity to have a reliable source of produce grown more locally than they had before.

The ability to construct greenhouse structures in city and urban areas offers an immediate impact for locals to have access to healthier food alternatives at a low cost. For example, in areas like Cleveland, there are roughly 28,000 empty lots found within city limits. Many of these areas don’t have nearby grocery stores or anywhere for people to buy fresh food and produce. According to the USDA, 25% of the Cuyahoga County Residents live in low-income neighborhoods at least a mile away from the nearest grocery store. These areas are commonly described as “food deserts” where inhabitants rely on other less healthy food sources like fast-food restaurants and convenient stores.

Ohio City Farms, for example, was founded in June 2010 and serves as the largest continuous urban farm in North America stretching 6 acres. They are also home to the Refugee Response Program that provides job training to refugees as well as income from selling produce to local customers and area restaurants. Tunnel Vision Hoops installed two 20' x 48' hoop houses to support the Refugee Response program that helped focus on four-season farming and increase overall farming capacity and production. Thanks to Tunnel Vision Hoops, people are benefiting on both sides of the spectrum by providing education and income to refugees and offering healthier, locally grown, food options at a reasonable cost to area locals.

Business benefit

The innovations of bi-directional cross anchors and the dome-shaped end wall have attributed to outstanding company growth since their start in 2010. In their first year of sales they recorded $65,000 and have since grown to $614,000 by 2015. Most recently, they are projecting to fall just short of $1M by the end of this year, 2016, taking them over 1200% growth in revenues in six years. What makes this more impressive is that because of the success of their products, they have not had to take on any debt or line of credit in order for the company to launch. In fact, one of their first customers made out a check before there was even a company bank account. The only shareholder outside of Todd and Carlton is an initial investor who exchanged property for manufacturing purposes for a 10% equity stake.

Social and environmental benefit

In the construction, the components of each design are carefully measured to avoid excess scrap and anything leftover is either reused or recycled. Anything that is left over is then set aside to be properly disposed of at the end of the year.

"The way we work internally with our process, growing food yourself is inherently more sustainable and promotes independent growers to make a living and encourage localized farming. Additionally, materials for our products are calculated to reduce waste in their manufacturing process, re-include scrap where possible, and compact any waste to recycle at the end of the year."

Hoop houses and high tunnels typically need to have their plastic sheeting replaced every 4-6 yrs. In these instances, Tunnel Vision Hoops carefully collects all old sheeting to properly recycle with the rest of anything gathered during their manufacturing process.

Thanks to Todd and Carlton's innovative design, Tunnel Vision Hoops’ innovative hoophouse designs have created a lasting impact on local communities, growing professionals, and countless individuals. They not only provide a solution to healthier food alternatives at a low cost but are conscientious of their impact on the environment. It is these efforts that contribute to the UN Global Goals of sustainable cities and communities as well as individuals health and well-being. With their efforts, Todd and Carl truly live up to their mission to supply farmers and growers with materials and supplies needed to grow more food, make more money, and live a less stressful, more enjoyable life.

Interview

Todd Alexander, Co-Owner, Founder