Temporary Grain Storage: Safeguarding Quality and Quantity

Welcome to the Grain Guy Fifty blog! As farmers and grain handlers navigate the complexities of modern agriculture, understanding the critical role of grain storage is required. Grain storage protects harvested grains and oilseeds from environmental factors while maintaining quality and quantity.

Temporary grain storage refers to short-term methods employed when permanent storage facilities are unavailable or impractical. The primary benefits include adaptability to various storage capacities, reduced upfront investment compared to permanent structures, and the ability to respond quickly to changing market conditions. However,  risks such as moisture intrusion and  pest infestations can compromise grain quality, potentially  leading to financial losses. Additionally, the handling activities associated with putting out and picking up temporary storage may increase handling losses more than typical permanent storage.

Temporary grain storage solutions are essential, especially during peak harvest seasons, logistics challenges, or  when market conditions necessitate holding grain for extended periods. In this post, we will explore various methods of temporary grain storage, including ground piles, and cover critical considerations such as planning, design, and operational tips to ensure optimal storage outcomes. We will also discuss the importance of cost feasibility studies, latest technology and measures to keep your grain secure. Join us as we uncover effective strategies for maintaining high-quality grain during temporary storage.

Keep in mind that there is no one size fits all approach to temporary grain storage. Variables such as type and quality of commodity to be stored, climate and environmental conditions, structure type and design, equipment selection, and expected duration of storage means that no standard operating procedures( SOP’s) can be provided that fits all situations. Each facility must develop its own procedures based on available resources and market demands.

Types of Temporary Storage Solutions

When considering temporary grain storage, there are several common options:

1. Ground Piles: These are simple, uncontained piles of grain that rely on the grain’s natural angle of repose for stability. They are often covered with tarps to protect against moisture.

2. Bunkers and Walls: Constructed from either self-built wooden or prefabricated metal sections, bunkers improve containment and capacity. Walls must be designed to accommodate the loading against them and secured into the ground. Wall height decisions depend on available layout space and desired storage capacity . Wall heights of 4’ or 6’  are common with  the limitation to go higher based on structural design and cost. In deciding on wall height includes consideration for  safety and ease of filling .

3. Rings and Covered Structures: These can be built with or without walls and may feature a structural tower in the center for filling. The choice often depends on the desired investment level and the risk of quality and quantity losses.

4. Non-Traditional Structures: Existing buildings not typically designed for grain storage can be repurposed, offering flexibility but potentially requiring modifications for ventilation and pest control.

5. Storage bags/Sausages: Provides an economical alternative to traditional storage but requires additional labor and equipment requirements. Their horizontal footprint demands more surface area to accommodate the same volume as vertical storage. ( Note – bag storage will be discussed, specifically in an upcoming post.)

Key Location Considerations

Selecting the right location for temporary grain storage is critical. Factors to consider include:

1. Access and Logistics: Ensure the site is easily accessible for trucks and equipment, facilitating the efficient movement of grains.
2. Drainage: Proper drainage is essential to prevent water from accumulating adjacent to or under the storage. Pad should be crowned.
3. Utilities: Availability of power for aeration systems or other technological enhancements should be factored into the planning.
4. Environmental Concerns: Consider the impact of dust emissions, noise from fans, and truck traffic on neighboring properties. Additionally, shading from adjacent tall structures can affect grain temperature and quality.

Design Considerations

When designing temporary grain storage, several critical aspects must be carefully considered to optimize both functionality and safety.

1. Wall Design and Structural Considerations:

The decision to use walls around temporary grain storage can influence both containment and protection. Walls can be self-constructed from wood or prefabricated metal, and their height can vary, typically topping off at four to six feet. Many prefabricated walls have perforation to aid in air flow. While a wall can help contain the grain and protect it from external threats, it is essential to consider potential safety hazards. For any storage that exceeds 48 inches in height, fall protection measures must be implemented to ensure the safety of workers during both setup and maintenance of the storage as well as filling and reclaiming activities.

• Base Materials:

The choice of base material beneath stored grain is another decision. Options range from bare grass or dirt, which can be cost-effective but offer little protection, to more durable choices like crushed limestone, asphalt, or concrete. Each option presents its own pros and cons. Be sure all pads are crowned in the middle :

1. Bare Grass/Dirt: Low cost; however, poor drainage and increased moisture risk, typically results in greater quantity losses due to contaminations from soil and excessive moisture.
   1. Crushed Limestone: Moderate cost; Good drainage and stability; may require significant initial labor for setup. Based on methodology used to pick up may result in higher quantitative losses to avoid picking up  lime or qualitative losses due to contamination of lime in the bottom few inches of the base.
   1. Asphalt/Concrete: Excellent durability and moisture control; higher upfront costs but minimal ongoing maintenance. Optimal solution to maintain grain quantity and quality.
2. Filling systems:

As with other design criteria there are several choices for filling temporary storage.

 a.  Utilize the permanent truck dumps at the facility, spout off the receiving leg to a pile adjacent to the facility or to a fixed conveyor to move the grain to a site so that the grain is not adjacent to the elevator structure.

•  Use self-dumping trucks discharging right onto a portable inclined screw conveyor.
• Grain bags require specialized filling equipment and tractors to power them.
• Use portable drive over pit(s) that can accommodate hopper bottom grain trailers feeding  a portable incline belt conveyor .  The belt conveyor may directly pile or be used to feed and overhead permanent filling conveyor running the length of the bunker.
• The temporary storage may have its own receiving pit feeding to a permanent leg that can fill a bunker or large ring.

• Covering Options:

Covers or tarps for temporary storage also warrant careful consideration. Options include heavy-duty, multi-year covers designed for durability versus one-year disposable tarps that are more economical initially but require annual replacement. Disposable tarps are much lighter and easier to handle. A restraint system in addition to the fans is required to secure the tarps .

• Aeration System Design:

An effective aeration system is crucial for maintaining grain quality in temporary storage. The fans are also used to create negative air pressure to hold the tarps in place. Factors to consider in designing the system include:

1. CFM/Bu Requirements: Understanding the necessary airflow rates for different grains and designs of storage is fundamental to ensuring proper storage conditions. The volume of air required for corn , soybeans , wheat, or other commodities varies greatly. Temporary storage may be used for different grains from year to year so the air installed should be based on the requirements of the grain  with the greatest air needs,  this probably will be corn.
   1. Fan Size and Number: Optimizing the size, number, and spacing of fans to achieve the desired cfm/bu. ratio is critical. If you are installing a new installation or making major modifications to an existing installation it is a good idea to contact an aeriation specialist to help with the design.
   1. Ducting Size and Placement: Properly designed ducting, along with a strategic layout of aeration tubes, will facilitate even airflow and uniformly maintain quality. Aeriation ducting placed on top of the grain under the tarps will aid in air flows. Again, if this is a new installation or a major modification to the existing system contact an aeriation specialist to help with the design. Be sure that all air ducts are securely fastened in place prior to filling.
   1. On ring designs with a permanent central tower, the tower structure can also provide air pathways for the center of the pile from ground level to the peak.

• Reclaim systems.

Like filling system there are many choices in design for reclaim systems:        

1. A front-end loader filling directly into a truck or feeding a portable incline conveyor.
2. Using a tractor fitted with a reclaim system and incline conveyor.
3.  Use of a large hoe or crane with a large capacity grab bucket filling into a hopper that loads trucks or directly to trucks.
4.  A permanent reclaim conveyor located in a tunnel beneath the pile. This will usually require a front-end loader to push grain to the conveyor gates.
5. Finally, grain bags require specialized reclaim equipment and tractors to power them,

Temporary Storage Operating Procedures and  Maintenance:

There are required actions that should be taken to manage temporary storage :

1. Site Preparation: Once a site location has been identified proceed with clearing any  obstructions, grading to drain water away from site and provide truck access, construct a crowned pad  , run utilities, install walls, fans , air tubes, and fill and reclaim equipment as designed. Be sure to check if a construction or operating permit is required before proceeding. If this is an existing site, go through your setup check list.
2. Grain Preparation: Grain going into temporary storage should be clean, cool, insect free, and have a uniform moisture content. Depending on the commodity, climate, amount of cfm/bu. available , and the expected duration the grain is to be stored, the moisture levels can be adjusted. It is recommended never to include old crop grains in temporary storage and do not use grains directly out of a dryer; let them cool and reach moisture and temperature equilibrium before placing not storage. If ambient air temperatures during harvest are excessive, try to cool grain in permanent storage before placing in the temp storage.

• Filling and covering: There are over twenty steps and sub steps in the filling and covering process. The steps will vary given the storage plan and the design of the storage so be sure to do a job hazard analysis of the filling process identifying each step and then create the appropriate SOP’s. Take particular care when putting covers on or taking them off, especially during windy conditions, to prevent damage and ensure safety.

4. Monitoring: Continuous monitoring of the stored grain is essential. Regularly check temperature, moisture levels, carbon dioxide concentrations, and any unusual odors that might indicate spoilage. This can be done using your senses of sight, smell, and touch or by means of specific monitoring equipment such as CO2 monitors. Whenever you are around the storage be sure to walk by the fans and smell the exhaust air and feel the temperature. If it smells sour or must or the air is too warm you will need to open the cover and investigate why and take any appropriate action. Part of monitoring should also include checking for pest  such as insects, birds, deer, or other species.

5. Picking up: When picking up a pile or emptying a ring or bunker it is desirable to pick up the entire quantity of grain in a continual action. If you are operating the pickup equipment and trucking be sure to do pre pickup inspections to ensure the equipment is ready to go. If you are contracting the pickup and trucking be sure to go over your sop’s , work rules, and expectations with the contractor prior to signing the contract.

6. Cleanup: After the grain is removed, perform a thorough cleanup of the storage area to prevent the proliferation of odors and pest infestations . This includes clearing debris and residues and addressing any potential safety hazards. Clean and store the walls, fans, and tubes. Prepare the site for future use now to save time next year.

7. Maintenance: Ongoing maintenance is crucial prior to and throughout the storage period. This involves checking and maintaining all equipment, aeration systems, inspecting covers, and ensuring that the base materials remain intact.

Technology considerations:

1. CO2 Monitors on Exhaust Fans: These monitors detect carbon dioxide levels in the stored grain environment. Elevated CO2 levels can indicate spoilage or the presence of pests or mold.

2. Handheld Infrared Heat Scanners: These portable devices may be used to  measure surface temperatures of grain piles. They help detect hot spots that can indicate spoilage or pest infestations. Scan range will not penetrate large piles.

4. Anemometers (Wind Speed Monitors): These devices measure ambient wind speed  around storage facilities and can reduce energy cost. On calm days when the fans are not needed or only a few fans are needed to hold the tarps in place they can be linked to the anemometers and fans can automatically be switched on and off as needed.

5. Sensors and Alarms for Fan Status: These systems monitor whether aeration fans are operating. If fans are off when they should be running, an alarm or message can be generated.

6. Security Cameras: Cameras installed around storage facilities can monitor for unauthorized access or tampering, enhancing security. Integration with motion detection can trigger alerts or notifications for suspicious activity.

By implementing these technologies  grain storage operators can ensure optimal conditions, minimize losses, and enhance food security.

AI:

Artificial Intelligence is quickly expanding in its reliabilities and capabilities and will offer more technology choices in the future. Here are some current and developing applications:

1. Monitoring Environmental Conditions: AI-powered sensors can monitor temperature, humidity, and CO2 levels, ensuring optimal storage conditions to prevent spoilage.

2. Predictive Analytics: Machine learning algorithms can analyze historical data to predict the best storage practices based on real time environmental and grain quality conditions.

3. Inventory Management: AI systems can track stock levels in real time, optimize loading/unloading schedules, and predict the right amounts of grain needed.

4. Quality Control: Image recognition and data analysis can assess grain quality, detecting pests or mold early and suggesting preventive measures.

5. Automation: AI can automate ventilation and aeration systems to maintain optimal conditions, reducing human labor and error.

6. Supply Chain Optimization: AI can enhance logistics by predicting demand and optimizing routes for transportation, schedule pickup and trucking  ensuring timely deliveries and reducing costs.

7. Risk Management: AI can identify potential risks related to storage conditions and supply chain disruptions, allowing proactive measures to mitigate losses.

Safety Considerations:

Temporary grain storage presents unique safety challenges that must be proactively addressed. Fall protection should be a priority and is required  when working around storage units with walls 48 inches high or taller. Also, while working on the sloped surfaces  there is a greater exposure to trips and falls. The movement and placement of heavy tarps also creates situations where there is  increased exposure to  back sprains and muscle pulls. Workers should be trained to recognize potential hazards associated with grain dust during setup and removal processes. Environmental exposure to the elements should also be monitored, ensuring that workers are equipped with adequate protection from sun, rain, or wind during prolonged exposure. Tarps should not be placed or removed during  high wind events.

Planning and Financial Feasibility:

A comprehensive planning phase should incorporate all major factors outlined, paying special attention to the financial implications of temporary storage. A cost feasibility study is invaluable, estimating all associated expenses such as site preparation, materials and equipment needs, utility provisions, labor costs, potential quality and quantity losses, depreciation of equipment, rental fees, contracted services, and trucking logistics. This financial planning should be aligned with the projected carry margins for the stored grain to ensure profitability.

Integration into Overall Storage Strategy:

Finally, temporary storage must not be considered in isolation. It should serve as an integral part of your overall storage or bin utilization plan. Having a clear strategy that accounts for both permanent and temporary storage solutions allow for maximum flexibility in responding to both market demands and crop conditions.

USDA U.S. Warehouse Act(USWA):

There are provisions in the USWA that if followed will allow licensed warehouse operators to apply for authorization to add emergency(temporary) storage under their license. For more information contact the AMS License and Storage Contract Branch in Kansas City, MO; 816-926-6474; submit requests, applications, or questions to warehousing@usda.gov.

Conclusion:

Temporary grain storage solutions are vital for effectively managing harvested grain and preserving its quality while maximizing profit margins. By understanding the risks and employing best practices in planning, design, and maintenance, grain handlers can safeguard their grain and enhance overall operational efficiency. As you explore various temporary storage options, remember that investing time in thorough planning and employee training is essential for success in grain handling and storage operations.

In my next post for Grain Guy Fifty, I will explore the use and feasibility of grain bags for temporary storage within a commercial elevator setting.

I encourage you to engage with this and previous 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. Whether you’re a farmer, 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 and share.

Your input is invaluable as we navigate the complexities of grain storage and handling together. Let’s work towards enhancing the industry standards and ensuring that our practices align with both quality and safety benchmarks.

Best,
Jim Voigt
“Grain Guy Fifty”

If you would like to schedule a review of your current storage strategies or develop some new strategies you can contact Grain Guy Fifty at jfvsolutions@hotmail.com or 217-855-4534.