For Progress Farms, drying and storing corn used to mean repeatedly rearranging augers and wagons to move grain from one bin to another. Bill Sheafer and Mike Elsner, who farm in partnership in Miami County, recently upgraded their facilities to cut down on labor requirements, increase their drying capacity and improve energy efficiency. They knew the improvements would be a one-time investment, so they planned carefully, Sheafer says. “We knew we had to do our homework the best we could and try to get it right.”

Sheafer and Elsner started with a row of seven grain bins of various sizes built 30 to 40 years ago. Two of the bins were equipped with drying floors and vertical stirring augers for in-bin drying. They’d use those bins for drying corn, and then rig up temporary transfer systems using augers, wagons and tubing to move the dry grain into other bins for storage. That system worked, but their drying capacity was limited and shifting grain from bin to bin was labor intensive and time consuming.

Even so, the old bins were in good repair, so Sheafer and Elsner wanted an update that would make those bins easier to use and also add storage and drying capacity. They put up an additional bin equipped with a continuous flow bottom drying system. As the grain is dried, it can be automatically drawn off the bottom of the bin and transferred to one of the other bins through a new five-inch blower system. That same bin can also be used for final storage of dried corn. “Essentially, our wet holding bin is a final storage bin,” Sheafer says.

The drying system blows heated air below the bin’s floor and up through the grain. The air removes moisture from the grain just above the drying floor and warms the grain higher in the bin. The system is efficient because so little heat energy is lost from the bin, Sheafer explains.

Sensors in the bin determine when the bottom layer reaches the desired moisture level, and horizontal augers at the bottom of the bin draw the dried grain to the center where it is carried out to the transport blower system. From there, the grain moves though the blower system under the driveway, up the transport tower and over to one of the storage bins.

Meanwhile, additional corn can be loaded into the top of the drying bin. The drying system can handle 800 bu. an hour of corn at 20% moisture, and can run 24 hours a day, Sheafer explains. That gives them enough drying capacity to avoid delays during harvest. In all, Sheafer and Elsner now have storage capacity for about 98,000 bu., including a couple of the older bins not connected with the blower system used for soybean storage.

Sheafer and Elsner also added a portable, drive-over pit auger system to replace the swing augers they had been using to fill bins. Now they can just set it up at the beginning of the season and run all the corn through it without having to move anything, Sheafer says. He also adapted a 30-horsepower motor to run the auger system, gearing down to turn at 540 rpm and adding a clutching system for easy starts. “I didn’t want to have to listen to a tractor and have to fill it with fuel,” he says.

Capturing an energy grant
As they planned for the grain system upgrade, Sheafer and Elsner discovered it could qualify for a Rural Energy for America Program grant through USDA Rural Development. To apply for the grant, which paid about 25% of the system cost, they worked with an electrical engineer who helped them calculate energy savings from the new system. He was able to estimate electricity demands based on motor sizes and calculate the Btu requirement per bushel. The energy savings from the new system is estimated at 99,763 kWh annually, which is the equivalent of nine homes.

The improvements to the grain system required a switch from single phase to three phase power to start larger horsepower motors. Luckily, Sheafer did not have to bear the entire cost of upgrading, as a cell phone tower next to the bins already required single phase power running from the road to back of the lane.

“We only had to pay the upgrade cost,” Sheafer says.

Sheafer and Elsner also discovered it would be practical to put up a small utility building to hold a transformer, fuse panels and other electronics. They were able to buy less-expensive components because they didn’t have to be weather-tight. “It actually saved us several thousand dollars,” Sheafer says. “The building became free.” They constructed the building on their own in their shop and moved it to the site with a roll back truck. They also saved money on construction by doing part of the earthmoving themselves when they weren’t busy farming.

Energy Efficiency Resources
Progress Farms reduced the cost for their grain system upgrades by qualifying for a grant from the Rural Energy for America Program (REAP). This program helps farmers and other rural businesses make energy efficiency improvements or install renewable energy systems. Such improvements can help improve profitability by reducing energy costs.

REAP awards grants from $1,500 to $500,000, as well as loan guarantees up to $10,000,000 for projects that qualify. Previously, the program has funded projects to replace grain dryers, upgrade fans and lights for livestock operations and install solar power systems to offset consumption of electricity.

REAP grants can pay for up to 25% of the cost of eligible projects and REAP loan guarantees can cover 75% of costs. Participants can use grants and loan guarantees on the same project, but the total funding can’t exceed 75% of the project costs.

For additional information on the program and future funding deadlines, check online at rd.usda.gov or contact one of Ohio’s rural development representatives: [email protected], [email protected], or [email protected].

AEP Program
Farmers with electricity supplied by AEP may also qualify for incentives to improve energy efficiency. The company offers free consultations with AEP Ohio Ag Energy Advisors, who can help customers evaluate potential equipment upgrades and new construction projects. The program provides cash incentives for customers who reduce electricity consumption by upgrading equipment such as fans, motors, and lighting.

The AEP advisors work with consumers to apply for the program and complete improvement projects. For additional information, check online at aepohio.com/solutions or call for a consultation at 866-276-949.