Each year, someone says, “It’s been a weird year.” That statement may be true, since raising, harvesting and storing a biological product such as grain vary each year. Weather, practices, marketing, equipment changes, personnel changes and grain variability make each harvest unique. One topic that never changes, however, is harvest and storage preparation. Each year brings many of the same requirements. With new equipment and upgrades in mind, managers can be ready for this ‘weird year.

The postharvest goal is to keep grain in the best condition possible for the best price and profit. The grain comes to the elevator in a condition we cannot control. But facilities, equipment, management of the grain and training of employees have a huge impact on quality from scale to the next stop along the supply chain. While planning and action are focused on the grain, employee safety must be considered at the same time. Many of the planning steps are the same. Good-quality grain makes for a much safer working environment. When grain goes into the bin easily and stays in good condition, it comes out more easily, helping keep personnel out of grain bins.

Keeping grain in good condition starts long before it comes to the elevator from the field. Cleaning, maintenance and repairs to grain handling equipment are near the top of the preparation list. If left undone, catastrophic consequences can occur, such as fires, explosions, facility damage and even loss of human life. Leaky structures, compromised bin structures, rusted doors and openings, clogged vents and exhaust fans, broken or missing bolts in steel bins, cracked concrete and gaps between bin rings all give moisture and insects an avenue to enter the grain and start biological activity that quickly deteriorates quality.

Questions managers should be able to answer at this point in the season might include:

  • What goals does the company have for this crop season?
  • Does the company have written standards and policies for cleaning grain bins?
  • Do employees understand the ultimate goal of storing grain and the warning signs of grain going out of condition?
  • Are employees aware of safety requirements, OSHA standards, company policies, proper personal protective equipment, confined space entry steps and how to do their jobs safely?
  • What training will employees need? How will they be assessed and training records saved?
  • Are bins and handling equipment in good condition? Are foundations in good repair, with no new cracks or shifting? Are all holes plugged or patched? How well do the doors and access points fit?
  • What equipment upgrades and renovations need to be done before loading new bins? Is it a good time to install that zero-entry sweep auger or build that closed-loop fumigation system?

Safety Equipment and Personnel Training

Often, new and seasonal workers are added for harvest, and existing employees need at least a yearly reminder of safety and procedural topics. All employees, seasonal and permanent, must be trained in safety procedures and facility policies. Be sure to document who was trained and what content was covered. Keep these records for at least three years in case of an OSHA inspection or an emergency.

Train all personnel on what to look for in grain quality and equipment. They can be the first line of detection for deteriorating grain and equipment malfunction. Before the rush of harvest, make time to educate employees so they work more safely and effectively. A major goal should be that everyone goes home safe and sound at the end of the day.

Cleaning and Inspecting

Removing stored grain is obvious in bins, but augers, trucks, pits, bucket elevators and areas around belts often are forgotten. This equipment is a common cause of fires and explosions. Cleaning is important all year long, but low storage inventory and slower truck traffic make this a good time to reach hard-to-access areas. Simple use of brooms, dustpans and explosion-proof vacuums or grain vacs can prevent significant risks. Make sure areas around the bins are free from vegetation and spilled grain. Refer to housekeeping procedures and document cleaning dates and activities.

Inspecting bearing temperature sensors and wear sensors on belts also is essential. These sensors can be secretly nonfunctional, depending on the facility’s electronic system. Like a household smoke alarm with a bad battery, bearing and belt sensors can give a false sense of security if they are not inspected and tested regularly.

Now is the time to replace, repair and test high-maintenance temperature cables for the incoming crop. Rises in temperature give managers and employees an early warning that grain condition is declining.

Replacing and Upgrading Equipment

If the facility has plans for unloading auger, drag, belt or sweep auger replacement, now is an optimal time to make those changes. Upgrading to zero-entry sweep augers has been considered a boost for a safer working environment.

Checking sump grating, electrical wiring, controls, guarding and safety equipment is extremely important. Keep records of inspections and any changes made to this equipment so management can make decisions on timely replacement and future maintenance.

Aeration systems and grain drying equipment must be inspected at least annually to ensure operation before new product comes into the facility. Warm weather and high-moisture conditions add demand on aeration and drying equipment. Poorly functioning or under designed aeration systems can lead to huge declines in grain quality and unsafe conditions when mold, insects and heat build in the grain. Electronic equipment is sensitive to dust, making preharvest inspection and replacement essential.

Every day is busy at a grain storage facility, but the time spent preparing now is critical to grain quality, employee safety and future organization profit. Use this summer and fall wisely to plan and prepare.

Resources can be found at:

GEAPS knowledge resource center: https://www.geaps.com/training... 

NGFA safety topics: https://www.ngfa.org/resources...

General safety training: https://grainsafety.org/traini...

Preparing Grain Bins and Flat Storages for Harvest: https://extension.okstate.edu/...

Preparing for Harvest and Grain Storage https://cropwatch.unl.edu/2018...