part 1: season extension with storage, cellaring & low tunnels with paul & sandy arnold
TRANSCRIPT
Season Extension with
Storage, Root Cellaring &
Low Tunnels
NOVEMBER 2013 Paul & Sandy Arnold
Pleasant Valley Farm
Argyle, New York
• INEXPENSIVE START-UP WITH SMART EXPENDITURES
• GOOD BUSINESS MANAGEMENT & RECORD KEEPING
• LABOR EFFICIENCIES TO MAXIMIZE PROFITS
• EFFICIENT PRODUCTION SYSTEMS & SOIL MANAGEMENT
• MULCHING AND WEED CONTROL
• PEST AND DISEASE MANAGEMENT
• SEASON EXTENSION-ROWCOVERS & FIELDHOUSES
• YEAR-ROUND HIGH TUNNEL PRODUCTION
• POST-HARVEST HANDLING AND CROP STORAGE
• CREATIVE MARKETING
OUR 10 KEY FACTORS TO REACHING OUR GOAL OF PROFITABLE FARMING
MISSION STATEMENT 12/94
1. A healthy, challenging, financially successful, family centered lifestyle.
2. Consistent, high quality, organic fruits and vegetables that make us proud.
3. A way of life that is an example to those around us.
4. Time to be an educator of environmentally sound agriculture to our employees, customers, and the community.
5. A rural environment that teaches good moral values and work ethics to our children, while providing time for fun and interesting opportunities.
• 5 Acres Mixed Diverse Vegetables
• ½ Acre Large Fruits
• ¼ Acre Small Fruits
• Perennials & Herbs From Seed
• 3-4 Acres Cover Crops
• Sell at 3 local weekly farmers’ markets in summer & two Saturday winter markets
• Hay fields used by local Beefalo farmer
PLEASANT VALLEY FARM 1988-1998
Storage for Year-Round Sales
GROW QUALITY CROPS TO HAVE QUALITY PRODUCTS
IN STORAGE
….AND QUALITY COMING OUT OF STORAGE
HARVEST AT PROPER TIME
•Netting for Insects
•3 types
•Great investment
•Biothrips netting for
thrips, flea beetle
HIGH QUALITY AT
HARVEST MEANS FASTER PROCESSING AND HIGHER POST-
HARVEST QUALITY
KEEP WEEDS OUT!
CLEAN CROPS MEAN
FASTER HARVEST
AND HIGHER QUALITY
OF PRODUCE…
WALK-IN COOLER FOR SHORT TERM COOLING &
LOW HUMIDITY STORAGE
CROPS FOR STORAGE
• Winter Squash
• Sweet Potatoes
• Onions
• Garlic
• Brussels Sprouts
• Leeks
• Potatoes
• Brassicas
• Greens
• CURE IN FIELD
OR IN STORAGE
• SUN SCALD
WINTER SQUASH
CLIP STEMS CLOSE TO
SQUASH
STACK GENTLY WATCH STEMS
WINNOW IN
THE FIELD FOR
EASE OF
LOADING
SORT FOR
1ST & 2ND
WASHING
WASH BEFORE OR
AFTER??
TUNNEL VS
OUTSIDE
• SOIL TYPE
• UNDER-CUTTER
BAR
SWEET POTATOES
TYPAR ROWCOVER
• HEAT
• DEER
• PLANT SKYDD
BINS
20 BUSHEL
SWEET POTATOES
BETTER
QUALITY
MEANS A
HIGHER PRICE
Pay attention to
details for
maximum profits
CURING SITE #1
JUNE 2010
CURING SITE #2
Optimum Curing for
Sweet Potatoes: • 85-90 degrees for 4-7
days at 80-90% humidity
• Longer if cooler
• Taste better with age
STORAGE AREA #3:
When supply down, move to heated cooler
CURING SITE #2
Optimum Curing for Winter Squash: • INDOOR: 80-90
degrees for 7 days with ventilation
• OUTDOOR: Field cure in sun for 5-7 days-CAUTION
• Longer if cooler • Taste better with
age
Varieties vary for
curing times
CURING SITE #2
• Vent-less
Propane
Heater—Or Electric
• Dehumidifier
• Plastic Bins-Decade $130
• TEW
Vegetable Washer
ONIONS
• Winnowed
• Field Cured
• Necks must be
dried down well
(at least 1 week in
sun)
• Beware of sun
scald
• Sorted as crated
ONIONS
ALTERNATIVE
CURED IN
GREENHOUSE
ON RACKS
ONIONS
STORAGE • TEMP 32
• HUMIDITY
60-70%
• SAME FOR
SHALLOTS
GARLIC
HARVEST
• FORK
CAREFULLY
• CLIP OFF ROOTS
• STACK GENTLY
GARLIC
WASH
• POWER
WASH VS
NO-WASH • EASY TO ID
SECONDS
• REDUCES PREP TIME
GARLIC
RACKING
• BUILD AS
GARLIC
COMES IN • AMPLE
SPACE
• FAN
GARLIC
RACKING
• Alternative
is in the High
Tunnel • Dries faster
• Shade cloth
if needed
GARLIC
DRYING
• EASY
ACCESS • READY FOR
SELLING!
WINTER STORAGE
“THE SHOP” ALSO
GREAT AREA FOR
GARLIC
STORAGE
WITH ONIONS
32 DEGREES
60-70% HUMIDITY
VERNALIZE??
WINTER STORAGE
• Homemade Box
• Reduce heating costs • Thermostat controlled
GROUND GARLIC
• GREAT USE OF SECONDS
• PEEL AND PUT THROUGH FOOD PROCESSOR
• DEHYDRATE ABOUT 12 HRS
• GRIND MEDIUM COARSE
• BAG IN MINI-ZIPLOCK
• SELL AT $1.50 FOR .03# (Heaping Tablespoon)
• VALUE ABOUT $30 PER POUND
• STORE IN SEALED GLASS JARS IN COLD ROOM (35 DEGREES)
BRUSSELS SPROUTS
STRIP LEAVES
CUT WITH
LOPPERS
DISEASE FREE?
BRUSSELS SPROUTS
• GRAIN BAGS
• OPEN FOR
VENTILATION
• STORE TILL
MID-FEB
• 32 DEGREES
• 95-100%
HUMIDITY
BRUSSELS SPROUTS
• Sell on the
stalk or strip
off sprouts
• Lose color in storage
• Can put
light on
them (15w)
LEEKS
• Dig with Fork • Sickle or cut
off some of
roots & very top
LEEKS
• PACK IN
GRAIN BAGS • STORE FEB+
• 32 DEGREES
• 95-100% HUMIDITY
• WINTER LEEKS
STILL IN FIELD
Invest in the
equipment that
makes
harvesting fast,
fun and efficient
Under Cutter/
Carrot lifter
Borrowed from
local farmer
CARROT HARVEST
Find the right
model of
equipment for
your needs
CARROT HARVEST
Roeters in Michigan
http://www.roetersfarmequipment.com
CARROT HARVEST
• BREAK OFF TOPS
• SORT INTO GRAIN BAGS
• WINNOW BAGS
• LOAD BY VARIETY
• STORE 32
DEGREES • 95-100%
HUMIDITY
CARROT HARVEST
• Carrot Harvester
• FMC • Single row • Bought Used
• Pros and Cons
POTATO HARVEST
• 1 ROW
POTATO DIGGER
• CHECCI
MAGGLI • 1 BUCKET PER
GRAIN BAG
• LOAD BY VARIETY
• GENTLE!
OTHER ROOT CROPS
• CELERIAC • KOHLRABI
• RUTABAGA
• TRIM TOPS &
ROOTS • PACK IN GRAIN
BAGS
LONG TERM STORAGE 6-8 MONTHS+
OTHER ROOT CROPS
• TURNIPS
• BEETS • RADISHES—
Small round
red & winter • TRIM TOPS
• PUT IN 5 GAL BUCKETS
• POUR IN GRAIN
BAGS
MEDIUM TO LONG TERM STORAGE
OTHER CROPS
• CABBAGE—
RED & GREEN • Storage #4 • Reaction
• Super Red 80 • CUT AT BASE
• PEEL EXCESS LEAVES
• PUT IN GRAIN
BAGS
LONG TERM STORAGE 4-5 MONTHS
OTHER CROPS
• CELERY
• SWISS CHARD • ESCAROLE • SPINACH
• CUT AT BASE • PEEL EXCESS
LEAVES • PUT IN STORAGE
BINS
• MIST IF NEEDED
SHORT TERM STORAGE 6-8 WEEKS
OTHER CROPS
• LETTUCE
• KALE • CAULIFLOWER • BROCCOLI
• CUT • PEEL OFF BAD
LEAVES • PUT IN OLDER
STORAGE BINS
• MIST IF NEEDED
SHORT TERM STORAGE 6-8 WEEKS
VEGETABLE TEMP F.
RELATIVE
HUMIDITY STORAGE LIFE
HIGHEST
FREEZING TEMP.
Beet, topped 32 98-100 4-6 mon. 30.3Brussel sprouts 32 95-100 3-5 weeks 30.5Cabbage, late 32 98-100 5-6 mon. 30.4Carrot, mature 32 98-100 7-9 mon. 29.5Celariac 32 97-99 6-8 mon 30.3Celery 32 98-100 2-3 mon. 31.1Garlic 32 65-70 6-7 mon. 30.5Kale 32 95-100 2-3 weeks 31.1Kohlrabi 32 98-100 2-3 mon. 30.2Leek 32 95-100 2-3 mon. 30.7Lettuce 32 98-100 2-3 weeks 31.7Onion, dry 32 65-70 1-8 mon. 30.6Potato, late 38-40* 90-95 5-10 mon. 30.9Radish, Winter 32 95-100 2-4 mon.Rutabaga 32 98-100 4-6 mon. 30.0Squash, Winter 50* 50-70 Varies 30.5Sweet Potato 55-60* 85-90 4-7 mon. 29.7Turnip 32 95 4-5 mon. 30.1
* Require curing http://www.ba.ars.usda.gov/hb66/contents.html
Adapted from Knott's Handbook for Vegetable Growers
ROOT CELLAR 20 FEET BY 30 FEET UNDER BARN
• 7 foot Ceilings • Insulated • Into bank on 2 ½ sides
ROOT CELLAR
Loaded via
assembly
line into the
root cellar
ROOT CELLAR
All crops loaded
by variety on
separate pallet or section of
pallets
Stored
Unwashed
ROOT CELLAR
Root cellar is
used all winter for
crates ready for market
Enables us to shut off the small
cooler & use it for
other type storage space
ROOT CELLAR
• Water tank in
corner from
washing station Filters dirt out
• Silver tarp over potatoes if
necessary to
prevent green
• Crates sizes and colors vary for different types of produce, rejects, etc
• Can be labeled with EXPO pen
ROOT CELLAR
Original cooling
system:
• Double thermostats with
fan exchanging
cooler outside air with warmer
inside air
• Window open and closed
ROOT CELLAR
Window for cold
air system okay
for late fall and winter, not early
fall and late
spring when temp outside not
cold enough
• Capacity is about
24 pallets with 18”
walkway
• Approximately 1
ton per pallet
when stacked to
ceiling
• Total = 24 tons
• Value of produce
stored: $85,000
Need to spray water
over bags periodically all winter to keep
humidity 95%+ The more the
compressor runs, the more water needed
Plan for misting system around ceiling perimeter
ROOT CELLAR HUMIDITY CONTROL
WEATHER STATION
SOLAR TEMP HUMIDITY WIND RAIN
REMOTE
SENSORS
• TRANSMIT
BACK TO
THE HOUSE
• ALARMS
WEATHER STATION
Scientific Sales, Inc.
• Wireless
• 4 Stations
• Computer • Davis Vantage
Pro II
• Repeater
Store fruits in different
facility Ethylene gas causes maturity and bitterness
Keep Root Cellar Clean and Tidy
Rotting produce also causes maturing
KEEPING QUALITY
WHAT WE STORE
WHAT WE STORE
WHAT WE STORE
SUMMARY
• ROOT CELLARING & STORAGE OF PRODUCE IS AN INEXPENSIVE WAY TO INCREASE SALES
• BENEFITS YEAR-ROUND MARKETING/INCOME
• SEPARATE STORAGE FACILITIES IMPORTANT
• MONITOR STORING CONDITIONS
• CURE PROPERLY FOR QUALITY
• KEEP CUSTOMERS HAPPY
Season Extension with Rowcovers and Fieldhouses (Low Tunnels)
Paul & Sandy Arnold
• STAY ON THE FARM
• LEVEL OUT THE INCOME
• CUSTOMER IMPACTS
• YEAR-ROUND WORKERS
SEASON EXTENSION
• Row Covers
• Field Houses
Makes crops
available year-round, more valuable, easy to
grow & economic
APRIL 10TH
ROWCOVERS
• Size • Brands
• Types
ROWCOVER TO GIVE VALUE AT
BOTH ENDS OF THE SEASON
COVER RHUBARB IN EARLY MARCH
Rhubarb will then start yielding
May 1st 30ftx27ft …about $125,000/acre
POTATOES PLANTED & COVERED IN APRIL PRODUCE IN MID-JUNE
FALL RASPBERRIES
Heritage Raspberries
Mow in March
Hoop and Rowcover
Ready in
August
Fully harvest
by hard freeze
Multiple Layers
Hooped Rowcover in November
Protects from the wind and snow
In dormancy for winter markets
EXTEND THE SEASON!
EXTREME PROTECTION!
STORAGE FOR LONGEVITY
• Rescued!
• Dried Out on Radiant heated
benches
• Rolled up in balls
• Labeled A, B or C
• Stored in Attic
1992—THE START OF FIELDHOUSES
=Low Tunnel, Hoop House, Caterpillar
FIELDHOUSES • Low Tech
• Inexpensive
• Temporary
• Built on Field
• Quick Set-Up
• Profit Centers
• Good for
Rotations
• Long Lasting
CONSTRUCTION OF FIELD HOUSES
• Scrap fencing posts 1 ¼ “ galv steel 18-24”
• Pounded in 4’ apart with board &
Sledgehammer– Alternative is rebar
• Slip 1” PVC pipes in about 6-8”
Duct tape ridge pipe down center
Duct tape support
braces on both ends
Dig trench one or both
sides—keep shallow
Pound in 4 pointed wooden stakes
Attach Pre-made end with 3” screws
Pull plastic tight
Lathe & secure with screws
Pull plastic tight
and fill in trenches
Rig venting with
ropes if necessary
Plastic PVC Piped Fieldhouse Finished! 2 men 4 hours Cost in 1993 was $600
Metal Hooped Fieldhouse for Snow Load
PIPE BENDING ON HOMEMADE JIG
MAKING GOTHIC PEAK WITH PIPE BENDER
20’ tunnel used for chickens also but same design
Side Rail makes them sturdy but time consuming to build
Cost in 1993 was $800!
www.newfarm.org/features/0503/arnoldsbuild.shtml
GROWING IN FIELDHOUSES
• Lettuce
• Spinach
• Beets
• Radishes
• Tomatoes
• Peppers
• Swiss Chard
• Basil
• **ONIONS
TOMATOES— 4” SOIL BLOCKS
INTERCROPPING
INTERCROPPING SPINACH & RADISHES MAKE THE MOST PER SQUARE FOOT
Home-made popper
GROWING LETTUCE IN FIELDHOUSES
MAKING SPEEDLING TRAYS LAST
•Seeded in greenhouse late February •Planted into field-houses starting in late March •8” apart in row •12” between rows
LETTUCE
•Plant 600 heads
each week for 3
consecutive weeks
•1800 Heads of
Lettuce
•Value of about
$4500 at $2.50 per
head
•Extrapolates to over
$145,000 per Acre!
SPINACH #1 IN FIELDHOUSES
Spinach planted 6” apart, Rows 12” apart Yields about 1150 row feet in one fieldhouse
Updated Irrigation:
•Simple to install
•Inexpensive & Timesaver
•Quick Disconnects
Spinach • We pick large leaves only
•Average $30 worth every
10 minutes
•Sell at $9 per pound
summer/$12 winter
VALUE IS OVER
$150,000 gross per
acre with more than
$4700 worth picked
in a 4-5 week period
in May-June
SOYBEAN MEAL OR PEANUT MEAL IS SPREAD AND PUSH-HOED IN 2 WEEKS AFTER PLANTING FOR A NITROGEN SOURCE FOR LETTUCE AND SPINACH AND OTHER CROPS IF NEEDED
Do plantings weekly outside when warmer to have continual supply
PEPPERS
Transplanted
From 1 ½”
Soil blocks
Or 4” Soil
blocks
MISTAKES MADE!
•Jingle Bell Variety •Started in Greenhouse about March 1st
•Potted up to 4” soil blocks •Planted out into fieldhouse May 1st
into straw •Problems, but…
•Not being in a
fieldhouse-
Value=$48,000 per
acre gross
•Season extended in a
fieldhouse-
Value=$64,000 per
acre
WINTER PRODUCTION
Seed in Greenhouse Sept 1
Transplant out Oct 1
Fieldhouse Built over it Nov 1
We Pick Only Leaves All Winter
WINTER USE
ROWCOVER & HARVEST
Great for
startup
Great for
spring &
fall
Stockpile
for Winter
FIRST TRIAL WINTER-WHAT NOT TO GROW!
BRIDGER ONIONS-SEEDED AUGUST 15TH
DEC 6TH-PLANTING DEC 10TH-HOOPS OVER
LOTS OF SNOW!
FORUM BOLTING IN LATE MAY BUT…
FORUM IN HIGH TUNNEL-LARGEST
2011-12: FORUM & BRIDGER IN 14X100’ FIELD HOUSE FOR TRIALS-PLANTED IN DEC
MAY: TAKE OFF PLASTIC—START HARVEST JUNE 1—STORED TILL DEC+ 2012-13 PLANTED UNDER ROWCOVER ONLY
ALTERNATIVE DESIGNS
Caterpillar design
Semi-permanent
Screw Anchors
Landscape Fabric
1 ¼” PVC punched into
ground
Tie and Stake ends
Tension of Strings allows
Venting
SUMMARY • CUSTOMER DRIVEN
• HELPS BOTTOM LINE
• ROWCOVERS INVALUABLE
• FIELDHOUSE - INEXPENSIVE START-
UP
• FAST PAYBACK
• FIELDHOUSE ROTATION
• EASY MAINTENANCE
NO BETTER WAY OF LIFE: RAISING FOOD YEAR-ROUND
WITH SEASON EXTENSION WHILE RAISING CHILDREN ON
THE GREATEST PLACE ON GOD’S EARTH: A FARM!!
THANKS AND HAVE A GREAT 2014 SEASON!
Alaska, Glacier 2011 Hawaii 2006