Grain Storage

Grain storage is a critical component of the food supply chain, found on farms, in commercial elevators, and processing plants. Simply put, grain storage involves keeping harvested crops in a safe place until they are ready to be sold or processed. This practice is essential for ensuring a consistent supply of grains throughout the year. By preserving harvested crops and protecting them from spoilage, grain storage enables supply chain participants to sell their grain at the most advantageous market time, bridging the gap between harvest seasons and market demand.

According to the American Farm Federation there are around 8,000 commercial grain storage facilities in the U. S., with 11.8 billion storage capacity representing around 47% of total grain storage capacity (as of Oct 2023). The remaining 53% or 13.6 billion, is found in on-farm storage.

Grain storage can be categorized into permanent storage, temporary storage, and ground piles. Throughout my fifty-year career in this industry, I’ve encountered many storage designs, including upright concrete, galvanized corrugated steel, welded steel, bolted steel, wood stave, tile, inflatable structures, sheds, caves, flats, bunkers, and piles. While I haven’t personally used grain bags—often referred to as sausages—I’ve researched and observed their application.

Over the years, grain bin sizes have increased significantly. When I first entered the industry, 48 to 60-foot diameter bins were standard, and a 90-foot diameter bin housing half a million bushels was considered “big.” Today, it’s common to see bins with diameters of 105, 132-135, and even 156 feet, holding over two million bushels. The typical concrete elevator I worked with was around 100’ in height in corn country and 130’ in wheat. Now, we can find concrete silos almost 400 feet high—such as the Swissmill Tower, at 387 feet, with a capacity of 35,000 metric tons.

Alongside the increase in bin size, the accompanying equipment has also expanded in size and capacity. Fill and discharge conveyance systems and aeration systems have evolved, with enhancements like zero entry bin sweeps.

You might be wondering, “Does this Grain Guy Fifty know anything about storing grain?” During my career with ADM, we had the largest licensed grain storage capacity in the U.S at around 450,000 000 bushels. Additionally, we managed temporary storage and/or ground piles for another 60 to 100 million bushels a year. My responsibilities and experiences have allowed me to observe grain storage practices on five continents and in 24 countries. This blog post is the first in a series where I will share my insights, experiences, and practical tips on grain storage. With that let’s look at a little bit of history on grain storage.

History

From the dawn of human history, grains have been a fundamental part of our diet. Early hunters and gatherers would find wild grains, harvest them, and store them in woven baskets or leather bags. As civilizations evolved, so too did their methods of storage. The ancient Greeks used amphorae—large pottery jars—to transport and store grain, marking a significant advancement in grain storage that contributed to the rise of cities and civilizations by reducing spoilage and protecting supplies from pests and enemies.

One of the earliest references to large bulk grain storage facilities appears in the Book of Genesis in the Bible. The story of Joseph highlights how he designed grain storage structures to feed Egypt during seven years of famine:

>“During those seven years, Joseph collected all the excess food in the land of Egypt and stored it in the cities. In every city he laid up the food from the fields around it. So, Joseph stored up grain in

such abundance, like the sand of the sea, that he stopped keeping track of it; for it was beyond measure.” (Genesis 41:48-49)

Evidence of large grain storage facilities can also be found in ancient Egyptian ruins. Around 3,500 years ago, circular mud-brick silos—shaped like beehives—were constructed, with heights of about 5 meters and diameters between 2 and 6.5 meters. Grain was added from a door at the top, while access for removal was through a lower door. Recent archaeological research at Tell Edfu has uncovered seven mud-brick silos estimated to be over 3,500 years old. The silos varied from 18 to 22 feet in diameter and were probably at least 25 feet tall.

There is evidence that cause some to believe the Egyptians may have been using mud brick enclosures to store grains as long as 9,500 years ago.

Another interesting example from my research involves the early Roman garrison outpost in England. To address storage challenges similar to what we face today, Romans built granaries with thick walls and column-supported floors, leaving void areas underneath allowing for airflow and drainage. This design helped keep grain cool and dry. Elevated structures reduced rodent losses, a timeless concern for grain storage.

During my travels, I encountered an example of 11th-century grain storage in Gdansk, Poland. This structure consisted of tile and wood, featuring an innovative elevation system that resembled a large hamster wheel, where men walked inside to lift cargo netted bags of grain to the top. The ingenious design of this mechanism illustrates the historical creativity employed to manage grain storage needs.

In North America, the evolution of grain storage became more pronounced in the 19th century. The first vertical silo was built in 1873 by Fred Hatch on a small farm in Spring Grove, Illinois. While this initial design was wooden and boxy, innovations followed rapidly, culminating in the first steel silo

on display at Chicago’s 1893 Exposition. The small replica of Hatch’s original silo now stands as a historical marker at Lyle Thomas Park in Spring Grove.

The first concrete silos also traced back to this era, with the earliest examples appearing in Minneapolis around 1880, thanks to the partnership of engineer Charles Haglin and Frank Peavey, who founded Peavey Grain in 1874. This collaboration introduced the jump form method of construction, significantly advancing silo technology. Meanwhile, in Europe, the first concrete grain silos were constructed in Braila, Romania, between 1888 and 1891, overseen by Romanian engineer Anghel Saligny using prefabricated slabs and reinforced concrete.

For an interesting short video of the Haglin/Peavey bin see this link: https://www.youtube.com/watch?v=b8mznEaXeN0

The Butler Company pioneered the concept of steel bin storage in 1908, taking materials used for livestock water troughs to construct the first steel grain bins, which measured only 12 feet in diameter. In the 1950’s Butler developed advanced manufacturing techniques that allowed them to produce larger, more efficient bins. Over the next few decades, advances in manufacturing allowed companies like Sioux Steel who first made steel bins in 1929, Superior in 1945, Behlen in 1950, SCAFCO in 1961, Sukup in 1963, Brock in 1975, GSI in 1972, Westeel in 1982 and many others domestically and around the globe to scale production and enhance bin efficiency significantly. . Today, approximately 95% of grain bins used in the US are corrugated steel bins.

In conclusion, grain storage is a fascinating and essential element of agriculture that has evolved significantly over the centuries. From ancient methods of using simple containers to the sophisticated, large-scale systems we have today, the journey of grain storage reflects advancements in technology, engineering, and our understanding of best practices.

If you have any comments or anecdotes about grain bin history or storage practices, please share—I’d love to hear from you! Thank you for stopping by, and here’s to navigating the world of grain operations together!

Looking Ahead

The next blog post will explore my thoughts on temporary grain storage and ground piles, examining the diverse types, emerging design trends, and operating tips. Join us as we delve into the past , present , and future of storage and its vital role in agricultural supply chain.

Join the Conversation

I aim for this blog to be an interactive space for discussion and idea-sharing. I encourage you to engage with the posts, share your thoughts, and ask questions. Together, we can explore the challenges and opportunities in the grain industry and embrace continuous improvement in our quest for excellence. As I share my experiences and insights in the coming posts, I hope to not only inform but also inspire others in the grain industry. Whether you’re a farmer, a grain handler, processor, OEM, engineer, contractor, or simply someone interested in the agricultural supply chain, there are always new lessons to learn and innovations to embrace.

Together, let’s continue to navigate this basic but complex and vital world of grain operations, ensuring food security for generations to come!

Best,

Jim Voigt

“Grain Guy Fifty”