part 1: season extension with storage, cellaring & low tunnels with paul & sandy arnold

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