Name : MANPREET KOUR

Id no. : 14AG63R20

Native place : Sriganganagar, Rajasthan

Email : kour.manu@gmail.com

Education : B.Tech Agricultural Engineering

University of graduation :University Of Agricultural Sciences , Bangalore

Year of passing out : 2014

Job experience (if any) : NA

Training : SRFMT&TI Anantpur

Projects : development of 3-tyne weeder-cum-hoe

Seminar on : Bag storage and its management

The seminar shows the technical aspects of bag storage in warehouses and hence gives ways to attain the maximum efficiency possible for storage of grains, keeping the present scenario of Indian grain storage capacity in view.

Bag storage and its management

Presented by:

Manpreet Kour14AG63R20

AGRICULTURAL AND FOOD ENGINEEING DEPARTMENTIIT KHARAGPUR

CONTENTS

• Introduction• Bag storage• Designing warehouse• Stacking of bags• Warehouse care and maintenance• Warehouse inspection• Data and statics

INTRODUCTION

It is estimated that 60-70% of food grain produced in the country is stored at home level in indigenous storage structures.The off farm storage is done mainly by traders, big farmers, cooperatives and government agencies such as the Food Corporation of India (FCI).The available storage capacity of these sectors is about 12% of total production and 41% of surplus production which comes to market for sale.

The Supreme Court of India in an order pointed out that: ―…In a country where admittedly people are starving, it is crime to waste even a single grain.

Natural contamination of food grains is greatly influenced by environmental factors such as type of storage structure, temperature, pH, moisture, etc .

During storage, quantitative as well as qualitative losses occur due to insects, rodents, and micro-organisms.

Almost all species have remarkably high rates of multiplication and, within one season, may destroy 10-15% of the grain and contaminate the rest with undesirable odors and flavors.

BAG STORAGE

This method is little used in developed countries but is widespread in developing countries. It is economical and well-adapted to local grain-transport and marketing conditions.There are several ways of storing grain in bags. The bags of grain can be stacked out-of-doors under tarpaulins, or placed inside storehouses, sheds or warehouses.Sometimes, especially for seeds, grain is stored in bags in refrigerated warehouses.

This method consists of conserving dried and cleaned grain in bags made of plant fiber or plastic, and neatly stacking the bags in carefully prepared areas.

DESIGNING A WAREHOUSE

Selection of site and Orientation

A raised site and good drainage to ensure no stagnant water in the vicinity of stores.Setting up the store with its longitudinal side on an East-West axis (less sun radiation on the building) or exposed to the main wind direction to create balanced temperature conditions and avoid the danger of condensation.Firm soil and good road connections to enable easy delivery and transportation of produce.Warehouses must not be built on black cotton soils, because these are weak and do not have sufficient soil-bearing capacity even for small warehouses.

 General Constructional Features

Not more than four corners and a simple and effective spatial design without any more angles, pillars, beams, windows or doors than necessary.

Offices and sanitary facilities should be separate from the warehouse.

Quality of the commodity to be stored should not get affected by physical factors such as moisture and heat.

Pesticides, fertilizers and other material should be stored separately.

FLOORING

A vapour barrier such as polyethylene foil of at least 0.2 mm thickness, or a 5 cm layer of bitumen should be used in the floor and in the first 25 cm of the walls.A smooth surface without any cracks or holes is easy to clean and does not afford insects any place to hide.

Floor should be at a height of 1 m above the ground.A floor hard enough to bear the load expected (concrete floor) should be used to prevents cracks.

WALLS

A white, water-resistant and, if possible, plastifying outer coat of paint should be used to reflect the sun radiation and to prevent penetration by moisture.If the supporting posts are thicker than the walls, it is important that the extra thickness is on the outside of the building so that the internal surfaces of the walls are smooth and free from projections.

Roof - bearing pillars should be integrated into the walls.The wall surface should be smooth without any cracks either inside or out.

ROOFING

Properly sealed connections from roof to walls to prevent any insects or birds from entering.Insulation under the roof in case of corrugated iron sheets to reduce effect of the sun radiation.Aluminium sheets or fibre concrete roofing do not become as hot as corrugated iron and create better storage temperatures.

Eaves overhanging the walls by at least 1 meter to ensure that the store is kept in shade and its walls are protected against rain.Eaves overhanging by at least 2-3 meters at the doors to enable vehicles to be loaded and unloaded when it is raining.

DOORSThe number of doors varies according to the size of the warehouse. If possible there should be at least two doors, so as to be able to rotate stocks on a 'first in, first out' basis.Tight-sealing hinged doors should be used to prevent rodents from entering. Metal doors are most resistant against any damage by rodents.Wooden doors should be fitted at the bottom with a panel of steel sheet of half a meter in height.Double sliding doors are recommended. They should be sufficiently large (at least 2.5 x 2.5 m) and close fitting.If swing doors are fitted they should open outwards in order not to reduce the storage capacity of the warehouse.

VENTILATION OPENINGS

Ventilation openings should have a size of 0.5 m²/100 m² storage area for incoming air (lower ventilation openings) and 1.5 m²/100 m² storage area for outgoing air (upper ventilation openings).The lower ventilation openings should be situated approx. ½ meter above the floor, the upper ones approx. ½ meter below the roof.Wire gauze and grilles in the ventilation openings and roofing over the ventilation openings should be provided.

ILLUMINATION

Most warehouse are illuminated by leaving several doors wide open during the hours of intense sunlight in tropical countries provides adequate illumination of the interior. Artificial lighting is justified only in warehouses which are regularly worked in during hours of darkness.

Translucent sheets in the roof are generally used, however it may involve the risk of spot heating of produce in the top layers of stacks underneath.Daylight filtering through ventilation gaps left along the tops of side walls are also used. This source of illumination is impaired by the installation of bird-proofing.

DETERMINING THE DIMENSIONS OF A WAREHOUSE

The dimensions of a warehouse are calculated mainly from:1.the Specific Volume of the principal product to be stored; 2.the Maximum Tonnage of this product which it is desired to store; 3.the Maximum Stack Height desired; 4.the extent to which Separation of Lots is desired.

(i) The Specific Volume of the Product

This is defined as the volume occupied by 1 tonne of the bagged grain.

Commodity Specific Volume (m³/t)

Wheat, milled rice, coffee 1.60Beans, peas, lentils 1.30Maize, sorghum, decorticated groundnuts, palm seed 1.80Soybeans, cocoa 2.00Wheat flour, maize meal 2.10Cotton seed 2.50

By multiplying the specific volume (in m³/t) by the quantity of grain (in t) to be stored, one obtains the volume (in m³) occupied by the bags in the storehouse.

(ii) Maximum TonnageThis parameter will depend upon the purpose for which the warehouse is required. The quantity calculated should also take long-term projected requirements into account.

(iii) Stack heightThe nature of the commodity and the type of sack to be used are factors to be considered.Some commodities, notably palm seed and cocoa, cannot be stacked very high because they compact easily.Sacks made of woven polypropylene have a tendency to slide on each other, and therefore should not be stacked more than 3 meters high.Jute sacks bind together better, and may be stacked up to 6 meters above the floor.

Stack heights for different grains

Furthermore, enough space must be left between the roof of the building and the tops of the stacks for a workman to move about freely.

(iv) Separation of lotsMaximum use of the warehouse is gained by storing products in one stack.However, it is usually necessary to separate lots; and, for better stock control.Spaces 1 meter wide should be left between stacks and the walls.The width of the passages between the batches can vary from 2 to 4 meters.

exampleA warehouse is required for the storage 1000 tonnes of maize in jute sacks in 4 separate lots. It is also assumed that the warehouse will be rectangular in plan, with the length approximately twice the width.From the specific volume of maize, the total volume of the stock will be: 1000 (t) x 1.8 (m3/t) =1800 m3

If the sacks of maize are to be stacked 5 metres high, the floor area required will be:

If length (L) = 2 x width (W), when:2W2 = 360 m2, or W = 13.4 metres

Keeping the example simple, let W = 12 m; then, the area being 360 m2, L = 30 m.If the stock is to be kept in four separate lots, each measuring 6 x 15 metres, then the following floor space will also be required:

a main handling area, 3 metres wide, along the axis of the warehouse; a gangway 2 metres wide, across the centre of the warehouse; and an inspection space 1 metre wide around the entire stacking area.

The internal dimensions of the warehouse will be:• Width (W) = 1 m + 6 m + 3 m + 6 m + 1 m = 17metres• Length (L) = 1 m + 15 m + 2 m + 15 m + 1 m = 34 metresgiving a total floor area of 578 m².

As the walls should be at least one metre higher than the intended stacking height: in this example 5 m + 1 m = 6 metres.

The percentage utilisation of the building will then be:

NOTES:•Similar calculations indicate that in small capacity warehouses (10 to 30 tonnes) only about 20% of the space is usable.•Medium capacity warehouses (50 to 100 tonnes) have only about 30% usable space.•Thus the larger a warehouse is, the more economical it will be in terms of cost of construction per tonne stored.

STACKING OF BAGS

CARE OF PRODUCE IN WAREHOUSES

(a) Prevent damp from the poor reaching the produceDuring construction a water barrier or membrane can be included in the concrete floor of the warehouse. Pallets and dunnage are used to form a barrier against damp.

DunnageDunnage is material that can be placed between the floor of a warehouse and the sacks of produce to prevent moisture moving from the floor into the produce.If made from sawn timber they are known as pallets and are suitable for handling by forklift trucks.

Pallets should be inspected and sprayed before use to avoid cross infestation and damage to sacks by protruding nails and split wood.Place the pallets in a way that enables a free current of air under the stack.

The pallets should be 10 cm high in order to facilitate aeration from below. As an additional advantage rodent infestation can easily be determined.

(c) Stack the sacks properly to allow:•optimal use of space;•ease of sweeping the floors;•ease of inspection of produce for the presence of rodents and insects;•ease of counting sacks; and•ventilation of sacks.

(b) Prevent damp from walls reaching the produceDamp from the roof is avoided through proper ventilation and using damp absorbing materials.

(d) Control insects and rodents by:•dosing all holes in doors, roofs, etc. where pests can enter;•repairing cracks in walls where pests can hide;•treating the building and produce against pests;•keeping the warehouse absolutely clean; and•removing and destroying any infected residues that might contaminate newly introduced pests.

Guidelines for Stacking Set the first layer of the stack carefully on the pallets -- this layer is fundamental for maintaining uniform stacks

Bond or interlace layers bags of grain or processed food to construct the stack.

 Line up bags or containers of food with the edge of a pallet. Place the same number of bags or containers on each level to make counting easy.

Attention must be paid to the following:Start exactly at the edge of the pallet.

Ears of bags (side where the bag is sewn) should be pointing inwards the stack in order to prevent grain spilling.

On every layer, work inwards from all four sides. If this results in gaps occurring in the middle of the upper layers, the stability of the stack will not be affected.Do not exceed stack sizes of approximately 250 t.

Stack the bottom layers with larger intervals than the top ones in order to obtain a slightly conical form of the stack which provides stability.

Storage management

Control insects and rodents

•Make sure the building is rodent-proof.

• Treat the building and protect against pests.

• Keep the warehouse clean.

• Close all holes in doors, roof, etc. where pests can enter.

• Repair cracks in walls where pests can hide.

• Remove and destroy any infested residues that could contaminate newly introduced produce.

PESTS CONTROLAddition of Substances to the Stored Produce(a) Admixture of Mineral al Substances: The most frequently used types of mineral substances are Wood ash, Inert dusts (laterit, clay dust, quicklime, etc.).(b) Admixture of Substances of Plant Origin: Fresh or dried leaves of different species of Annona, Hyptisspicigera, Neem or Melia.Mechanical Methods•Removal of pests, infested grain or cobs by hand, Sieving, Winnowing, Moving the grain (shaking, restacking).•The Use of Heat: Spreading out the produce in the sun (larvae living in the grains will be killed, the adult insects which are sensitive to heat and light will flee).•Fumigation: aluminium phosphide tablets or pellets, granular calcium cyanide,  Carbon tetrachloride, methyl bromide, Phosphine etc.

1. MaintenanceWarehouse managers and storekeepers must periodically examine the warehouse for structural deficiencies.Repair leaking roofs.Seal cracks in the warehouse floor, wherever possible.Close any openings in the eaves, walls or foundation where birds or rodents can enter.2. CleaningKeeping warehouses clean reduces dust, cobwebs, bird droppings and the risk of insect and rodent infestation. The warehouse manager or storekeeper should develop a cleaning plan which assigns specific duties to warehouse staff. The following table provides one example for a cleaning plan.

MAINTENANCE AND CLEANING

Warehouse Cleaning PlanDaily Clean spillage as it occurs.

Sweep the floor and dispose of the sweepings.

Weekly Sweep walls and sides of stacks thoroughly.Clean debris in the area surrounding the warehouse.

Monthly Sweep roof beams.Clean ventilators.

The following table lists areas of the warehouse to be inspected and evidence that may indicate problems

Area to be inspected:

Inspect for:

Outside the warehouse

CleanlinessCondition of roof, walls and windowsSecurity--fences, guards, locked doors and windows

Inside the warehouse

Condition and cleanliness of ceilings, floors and wallsAdequate ventilationPlacement of rodent baits/trapsPresence of hazardous substances such as chemicals and pesticidesPresence of fire extinguishing equipment, dates not expired

WAREHOUSE INSPECTIONS

Area to be inspected:

Inspect for:

Food storage area

Distance between stacks, and between stacks and wallsInterlaced or bonded stacksUse of pallets free of exposed nails or wooden splinters which may tear bagsSegregation of damaged foodInsect infestations -visual and soundsRodent or bird infestationsStale food which has been stored too longGermination of grain in sacksShort-weight containers

Warehouse office area

CleanlinessAdequate shelvingAdequate lightingCondition of office equipment

 (From CARE's Commodity Storage and Handling Manual, 1992)Take action based on the guidance listed in the following table.

When inspecting stacks, climb to the top and spot check bags or containers underneath top layer, and from the side carefully look in between bags or containers.

Controlling Damage to Food GrainsType of damage

Evidence of damage Methods of control

Action necessary

Leaking, broken or torn bags.

Spilled food in transport vehicle. Food spills from containers during unloading.Bags are torn and containers are dented or crumpled.

Handle properly--do not throw, stack too high or use hooks.

Repackage food fit for human consumption. Inspect sweepings. Prepare Loss and Adjustment Reports and enter transactions on stack cards and in warehouse inventory ledgers.

Wet, stained or moldy bags.

bags are wet to the touch or dripping.Unusual smell (moldy or chemical).

Ship in waterproof holds or in adequately sealed cargo containers.Insure adequate air circulation.

Food dampened by rain may be dried and reconstituted.Prepare Loss and Adjustment Reports and enter transactions on stack cards and in warehouse inventory ledgers.

Rodent or bird infestation

Excrement on the floor or stacks Gnawed bags, Footprints in dust Nests

Close holes or openings in walls, floors and ceilings. If possible place screens over windows and ventilation openings, Cats are effective in controlling rodents, Traps can be set

dispose of food declared unfit for human consumption.Prepare Loss and Adjustment Reports and enter transactions on stack cards and in warehouse inventory ledgers.

Insect or moth infestation

Flying insects, dead insects or larvae on the floorbags have small holes the bag Strong odor

Keep both the outside and the inside of the storage facility clean and free of dust and debris.

Inspect and fumigate; dispose of food declared unfit for human consumption.Prepare Loss and Adjustment Reports and enter transactions on stack cards and in warehouse inventory ledgers.

Insect or moth infestation

Flying insects Live or dead insects or larvae on the floorTraces of insects or larva in dust Grain bags have small holes and excessive dust Noise heard inside the bagIrregular holes in the grain or beans Strong odor

Keep both the outside and the inside of the storage facility clean and free of dust and debris.

Inspect and fumigate; dispose of food declared unfit for human consumption.Prepare Loss and Adjustment Reports and enter transactions on stack cards and in warehouse inventory ledgers.

AGRICULTURE WAREHOUSING IN INDIA DATA AND STATISTICS

REPORT OF NATIONAL STATISTICAL COMMISSION ON STORAGE OF AGRICULTURAL PRODUCTS

India produces about 150 million tonnes of food grains per year. Production has been steadily increasing due to advancement in production technology, but losses have remained static at 10%.The Ministry of Consumer Affairs, Food & Public Distribution in a recent press release indicates that as of 1 June 2011 the capacity with FCI and other public agencies to store grains is 623.65 lakh tonnes of which 28.5 per cent (or 177.69 lakh tonnes) is under cover and plinth in the open.The main agencies storing surplus grain, and the amounts involved, are as follows: FCI-7.7 million tonnes (Mt) Central Warehousing Corporation- 2 Mt State Warehousing Corporation-24 Mt grain marketing cooperatives-4.5 Mt some state governments 1.9 Mt.

An average of 6% out of a total 10% loss takes place during storage of food grains. For scientific storage, drying of food grains to a safe moisture level is a top priority. The use of dryers to dry surplus grain kept for storage is not common. The main reasons for this are a lack of awareness among the rural populations, high capital cost, and no incentive given for farmers to produce properly dried grain.

Private Sector in Storage Private sector Corporations in some cases financed by term lending agencies are coming of age. For example IDFC has given large loans to Private Corporations engaged in constructing storage for agricultural commodities. In some cases these companies use the receipts for commodities stored by them as collateral for financing farmers. These are very interesting ways of financing what is called the value chain in Indian agriculture.

REFRENCES

D.L. Proctor, “Grain storage techniques - Evolution and trends in developing countries”, In: FAO agricultural services bulletin no. 109 by:  Agriculture and Consumer proecion, M-17 ISBN 92-5-1 03456-7.

Geoffrey C. Mrema, Hakgamalang J. Chepete, Januarius O. Agullo, Lawrence O. Gumbe, (2011) Rural structures in the tropics Design and Development, Rome: CTA publications.

Joost Gwinner, Otto Muck, Rudiger Harnisch, (2001) Manual on the Prevention of Post-harvest Grain Losses, GTZ publications (pp 60-108).

Prof. S. N Naik and Dr. Geetanjali Kaushik , (2011) Grain Storage in India: An Overview, http://www.vigyanprasar.gov.in/Radioserials/Grain%20Storage%20in%20India%20by%20Prof.%20S.%20N.%20Naik,%20IIT%20Delhi.pdf

Food Resources Manual , Food Security Unit, CARE USA, (August 1998)

National Statistical Commission, Ministry Of Statistics And Programme Implementation, Government Of India, (2013) Report Of The Committee On Statistics Of Agriculture And Allied Sectors, New Delhi.