A grower planning a greenhouse business sooner or later faces a choice: a tunnel or an industrial film greenhouse. Both work all year round, cover the needs of commercial growing and are built from galvanised steel with a film covering. But the difference between them lies not in details — it lies in scale, technology and economics.
The differences are easier to grasp when the structures are compared by specific parameters. That is what we do in this article — with figures, a table and recommendations for different types of business.
What each type is
A farm tunnel greenhouse is a free-standing arched structure 9.6 m wide with a ridge height of 5.2 m. The frame is assembled from reinforced flat-oval arches with a 63×52 mm section spaced 2.5 m apart. The columns are 60×60×2 mm profile on 50×50 mm piles. The covering is double light-stabilised film of 180 microns with an anti-condensate layer, UV protection and inflation between the layers. Tunnel lengths start from 30 m. The structure is designed for medium-sized farms.
An industrial film greenhouse is built differently. Several tunnels are joined into a multi-span structure, which gives quite different possibilities in area and microclimate control. The width of a single span is 8.0, 9.6 or 12.8 m. The columns are heavier — 80×80×2 mm, the foundation piles 70×70 mm. The trellis height reaches 3.5–5.5 m, which is critical for tall crops. The walls are made of polycarbonate 6, 8 or 10 mm thick, and the roof is covered with the same double film with inflation. Block lengths start from 50 m.
Comparison table
| Parameter | Farm tunnel | Industrial film (multi-span) |
| Type of structure | Single tunnel | Multi-span block |
| Width | 9.6 m | 8.0 / 9.6 / 12.8 m |
| Ridge height | 5.2 m | 5.2 m |
| Trellis height | 3.0 m | 3.5–5.5 m |
| Columns | 60×60×2 mm | 80×80×2 mm |
| Foundation piles | 50×50 mm | 70×70 mm |
| Arch/column spacing | 2.5 m | 2.5–3.0 m |
| Roof covering | Double film 180 microns + inflation | Double film 180 microns + inflation |
| Walls | Film | Polycarbonate 6/8/10 mm |
| Ventilation | Manual or automatic (side + ridge) | Active Climate: recirculation, conditioning |
| Summer cooling | Natural ventilation | Active conditioning |
| Doors | Sliding 3×2.7 m | Sliding 3×3 m + automatic sectional |
| Minimum area | from 1,000 m² | from 1,000 m² |
| Entry cost | Lower | Higher |
| Heating savings | Double film reduces heat losses | Active Climate: –25% of costs |
| Yield increase | Baseline | +20% (Active Climate) |
Ventilation and climate: the main difference
Probably the most noticeable difference between the two types of greenhouse is the microclimate control system.
A tunnel greenhouse is fitted with side ventilation (manual or automatic) and automatic ridge ventilation driven by a geared motor with rack and pinion. In summer the air is cooled by natural draught. In winter the heat is held by the double film with its air gap. For most farm tasks that is sufficient.
An industrial greenhouse uses Active Climate technology. Instead of conventional vents there is an air recirculation system with air sleeves, conditioning and even distribution of CO₂ throughout the volume. The number of vents is reduced by 90%, and a constant slight positive pressure is maintained inside the greenhouse. The result is precise control of temperature and humidity at any time of year, protection against pests and a 25% reduction in heating costs.
Is Active Climate worth paying extra for? It depends on the task. If you grow tomatoes or cucumbers in an extended cycle on an area up to 3,000–5,000 m², tunnel ventilation will cope. If it is year-round production on industrial areas, where every percentage point of yield affects profitability, the technology pays for itself.
Covering and thermal insulation
The roof is the same for both types — double film of 180 microns with an inflation system. The air gap between the layers works like a thermos and reduces heat losses.
The difference is in the walls. A tunnel greenhouse has film walls, an industrial one has polycarbonate 6, 8 or 10 mm thick. Polycarbonate holds heat better and withstands mechanical loads, but it increases the cost of the structure.
For tunnel greenhouses the film suppliers are named specifically — Politiv (Israel), Plastika Kritis (Greece), Greenplastik (Turkey). The warranted service life of the film is 5 years.
Economics: cost of entry and return
A tunnel greenhouse is cheaper to build. A simple structure, fewer materials, fast installation. For a grower with a limited budget it is a way into the greenhouse business without large capital investment.
A multi-span industrial greenhouse requires more investment at the start. A reinforced frame, polycarbonate walls, the Active Climate system and automatic sectional doors all cost money. But the running costs are lower: 25% savings on heating and a 20% increase in yield shorten the payback period for large farms.
Want to work out which option is better for your farm? Send a request for a calculation — NIVA GREENTECH engineers will prepare a comparative estimate for your area and crops.
When to choose a tunnel greenhouse
A tunnel structure suits you if:
- The business is a family farm or medium-sized;
- The construction budget is limited;
- Seasonal or extended-season growing is planned;
- The greenhouse area is from 1,000 to 5,000 m²;
- The main crops are tomatoes, cucumbers, peppers, leafy greens, seedlings and berries;
- There is no need for year-round industrial production.
A tunnel greenhouse is a working tool for a grower who values simplicity and sensible investment.
When to choose a multi-span industrial greenhouse
An industrial film greenhouse is justified when:
- The business is moving to year-round industrial production;
- The greenhouse area exceeds 5,000 m² with room to expand;
- Tall crops are grown that require a trellis from 3.5 m;
- Precise control of the microclimate — temperature, humidity, CO₂ — is critical;
- Heating accounts for a significant share of the production cost;
- The aim is to maximise the yield from every square metre.
A multi-span structure scales more easily than a set of separate tunnels. New spans are added to an existing block without interrupting the production process.
Frequently asked questions
Can you start with a tunnel and move to an industrial greenhouse later?
Yes, and many businesses do exactly that. A tunnel greenhouse lets you refine the growing technology, build up sales channels and gain experience. When production outgrows what the tunnels can do, the grower moves to multi-span structures with a clear understanding of their real needs.
Which type of greenhouse is better for tomatoes?
Both work. For farm volumes in an extended cycle a tunnel greenhouse with a 3 m trellis height is sufficient. For commercial production with tall hybrids a multi-span greenhouse with a 4–5 m trellis and an Active Climate system is better.
Why is double film better than single?
Double film with an inflation system creates an air gap between the layers. Heat losses fall by 30–40% compared with a single-layer covering, and condensation is drained away thanks to the anti-condensate layer.
In which regions do both types work?
NIVA GREENTECH builds greenhouse complexes across Russia and in the CIS countries — from southern regions to northern latitudes. The structures are calculated for the snow and wind loads of the particular region of construction.
How long does construction take?
The timing depends on the area and the equipment package. A tunnel greenhouse goes up faster thanks to its simple structure. A multi-span industrial one takes more time to erect the frame and install the Active Climate system and the utilities.
The next step
Choosing between a tunnel and an industrial greenhouse is a choice of scale and technological level. Both options solve the task of commercial growing, but at different stages of a farm’s development.
NIVA GREENTECH has been designing and building greenhouse complexes of both types since 2007. Our own steel structures plant, more than 100 hectares of completed facilities and a full cycle — from calculation to installation.
To get the cost of your project, send a request on the website or contact the sales department for a consultation.
