For many areas, growth in corn production has been outpacing the rate at which new grain bins are being built. This has many commercial grain facilities, including some ethanol producers, looking to alternative storage methods, like ground piling. However, some facilities have employed a different temporary storage solution in an effort to better protect their grain quality: grain bags.Unlike bins, grain bags offer the benefit of virtually unlimited storage. When one bag fills up, another can be started. The concept originated decades ago in South America, where lack of infrastructure compelled farmers to devise alternative grain storage systems. Eventually, the idea worked its way north, with grain bags and bagging equipment now being manufactured in North America.As a result, the availability of bags, equipment, and parts has become much more reliable here. These products are sold and supported by many local dealers, helping to keep customers running in the busiest times of the year. Today, this solution has been adopted by both farmers and commercial grain facilities throughout the U.S. and Canada. Nonetheless, there is still a general lack of education about grain bags, which has caused some to be hesitant to implement this system in their operations.The Equipment&nbsp; Farmers that bag their grain typically utilize 10-foot-diameter bags. Commercial operations, however, often use 12-foot-diameter polyethylene bags that are up to 500 feet long. This is the largest size bag available for purchase. The specialized polyethylene bags are often made of three layers with UV protection and warranties lasting as long as 18 months.A grain bag loader is used to fill the bags. Grain can be dumped into the loader’s top hopper using an auger, but most customers add a swing hopper for dumping hopper-bottom trailers. The grain bag loader can transfer grain at rates up to 30,000 bushels per hour—faster than many older elevators can unload trucks.Today’s grain bag loaders have numerous features to make the job easy. For instance, some have a jib crane and trolley system that helps to self-load heavy bags onto the machine. Specialized bag pans, cradles, and bag loading tarps are other items that help operators easily and confidently load and fill bags. Other benefits like precise brake adjustment help keep users fully in control of the process.To empty the bags, a grain bag unloader is used to roll up the bags while transferring the grain into a trailer. In fact, many unloaders can fill a 1,000-bushel trailer in only about seven minutes.Although slightly more complex than grain bag loaders, the unloaders also have numerous features designed to simplify things. Some manufacturers offer training videos and on-site instruction to give operators peace of mind when loading and unloading grain bags.How Bags Work&nbsp; Grain can be kept safely for months in bags without losing condition. Once the bags have been sealed, the oxygen level is reduced, and the concentration of carbon dioxide is increased. This environment virtually eliminates fungal diseases and insects. The airtight environment also slows down the natural metabolic process that leads to increased temperatures in the grain, extending the storage life of the product.Although grain bags are intended for storing dry grain, some commercial grain buyers have had success storing higher moisture corn for shorter periods of time. Thanks to the airtight environment inside the bags, grain comes out of the bag in the same condition as it goes in.Bagging Tips&nbsp; Much of the success in grain bagging comes from proper site selection and bag placement. Ideally, bags should be placed on a clear, elevated, slightly sloped, and firm piece of land with no chance of flooding. If any areas on the site do not drain naturally, then drainage channels can be dug to shed water away from the storage site. Keep in mind that poor traction on the site will make it difficult to maintain the proper filling of the grain bag during the loading process. It can also cause problems for trucks entering and exiting the site to load and unload.Next, it is recommended to position grain bags north to south on the storage site, if possible. This will allow the grain bags to be exposed to the sun evenly. Starting the grain bag on the highest elevation of the storage site will make it easier to load bags while also preventing moisture from entering the bag at either end. Also, be sure to maintain adequate space between the grain bags, allowing room for the unloading equipment and trucks to travel between them.After filling grain bags, it is best to check them weekly for punctures, especially from rodents, which can cause the most damage. Small areas of damage can be repaired with the bag manufacturer’s specified tape. However, if the damage is too great to be repaired with tape, the bags should be emptied and the grain loaded into a new bag. Unrepaired punctures in the bag can let in moisture, potentially leading to spoilage.Costing only pennies per bushel, grain bags can provide cheap insurance for preserving grain quality when the bins are full. And the transfer rates are fast enough to keep any operation moving. For ethanol producers that haven't already done so, it may be time to consider bags as an alternative storage solution. Author: Tryg Waterhouse&nbsp; Director of Sales, Loftness&nbsp; info@loftness.com&nbsp; 800-828-7624&nbsp; www.loftness.com

2024-02-06 - Bagging When the Bins Fill Up (Ethanol Producer Magazine)

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Rather than open-air storage, some commercial grain operations are turning to massive, polyethylene bags. When properly maintained, they can keep grain safely for months. 

Bagging When the Bins Fill Up

Bagging When the Bins Fill Up

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Bagging When the Bins Fill Up