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  Most of Greenbrier's products are wholesaled to East Coast garden centers and rewholesalers. | |||||
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Keeping plants upright More pictures | |||||
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By Todd Davis Greenbrier Nurseries Inc., located in the scenic West Virginia mountains, is an evolving company. Owner Jim Monroe Jr. knows that with change the company has to develop better, more efficient ways to do things. The nursery is growing in part due to the Talcott, W.Va., climate. With an elevation at about 2,000 feet, summer highs aren't all that high. "I guess we have the best of both worlds," Monroe said. "We can grow a lot of crops in the summer that can't be done elsewhere." For instance, Greenbrier grows about 72,000 Chamaecyparis pisifera 'Gold Mop' per year, a crop that can be produced in few places during summer in the United States. "Anywhere else, such as the Gulf Coast or even around Portland, Ore., its foliage tends to burn in late summer," Monroe said. "But here it won't scorch." But with cool summers also come harsh winters where low temperatures can reach minus 25F. Because of this and frequent heavy snow loads, Greenbrier needs stout coldframes. While heavy snows don't occur every year, 40 inches annually isn't uncommon. In fact, the company has seen 3 feet of snowfall in a single night. "We need coldframes to be heavier duty than most people need. Plus we have to have peaked roofs because rounded tops wouldn't shed snow well enough," Monroe said. All covered Nearly all of Greenbrier's crops are overwintered in 70 unheated coldframes, most measuring 22 feet wide and 200 feet long. The structures, rated to withstand 70 pounds of snow per square foot, are covered with 6-mil white polyethylene in winter. "If you were to go two hours to the south, you wouldn't need to overwinter as many things with protection. But here even things like junipers need protection," Monroe said. "About the only thing we grow that will overwinter outside in a container is spruce." It takes a four-man crew about two weeks to cover all of the coldframes with glazing. The company's goal is to have the chore completed by Thanksgiving. When temperatures reach 0F, plants are covered with Reemay fabric from Precision Fabrics Group Inc. for additional protection. When snow is predicted, all managers are contacted to create a plan in case crews are needed to hand shovel snows that could endanger structures. In 1985, the company had three houses collapse due to snow loads, but Greenbrier has had no problems since. When warm weather arrives in winter, coldframe doors are opened and Reemay cloth is removed. Beginning in early spring, slits are cut in the poly sheets for additional ventilation. Employees begin uncovering coldframes in March, allowing less cold-sensitive crops to come out of dormancy naturally. "This is especially important for flowering shrubs since we want them to bloom at their normal times," Monroe said. Other crops, such as Japanese maples whose foliage is more sensitive to cold, may not be uncovered until May 10, the area's average last frost date. Adding mechanization For three years Greenbrier has used a potting machine from Ellis Manufacturing. Monroe said it has been one of the company's best investments. "It cost $50,000, which was a huge investment at the time, but it has paid off tremendously," Monroe said. "Before we would have three guys planting 3-gallon pots. They could pot, load and move probably 1,000 pots in an eight-hour day. Now with the machine and maybe two more people, we can do 5,000-6,000 a day." Potting costs per unit are estimated to be one-tenth what they were. In addition, having to spend less time potting has freed up employees' time to do other chores such as spraying or weeding. "It has given us the time to do what it takes to produce a quality crop," Monroe said. The machine has also given Greenbrier more consistent crops. Rather than having some employees planting crops deeper than others or sometimes off center, the liners are placed in containers more consistently. "It also leads to a better work environment because the work is shared more evenly. You don't have one or two employees doing the bulk of the work," Monroe said.
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