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THE DECISION to invest in new storage and handling facilities in the last few years has reaped rewards for Eastern Farmers Co-op and Farmers Elevator & Exchange, both in terms of efficiency and environmental friendliness. In fact, the Mid America CropLife Association (MACA) recently recognized the South Dakota and Iowa dealerships for the environmental protections they built into their new facilities. The dealerships were two of the five recipients of MACA's 2005 Water Guardian awards (see sidebar).
MACA, which has sponsored the Water Guardian award program since 1991, works with state associations to recognize agricultural businesses and individuals that promote environmental stewardship of the crop protection industry, concern about water quality and overall protection of the environment.
New fertilizer plant
Eastern Farmers Co-op, a regional CHS cooperative in Worthing, SD, decided to close three of its fertilizer plants that had been built in the 1960s and replace them with a brand-new 20,000-ton dry fertilizer plant in 2004. Starting new was a better option than to remodel the older facilities to bring them into compliance with state regulations, says Tony VanOverschelde, location manager for the cooperative. Eastern Farmers Co-op serves customers in a 100-mile radius of Worthing. Corn, soybeans and alfalfa are the main crops grown in the area.
The cooperative decided to build on a 175-acre parcel of land outside of town that had no immediate neighbors. The three older plants had been located in towns, and with traffic and other issues, the move was probably the best decision for all parties concerned, VanOverschelde explains. The new facility also features railroad track siding. Most of its fertilizer is delivered via rail unit trains.
In addition to handling dry fertilizer, the facility stores 1,200 tons of liquid fertilizer and has 12 bulk tanks for storing crop protection products. All dry fertilizer is handled indoors. The dealership also uses mineral oil to reduce dust and installed dust socks in the tower to collect residual dust coming from the dry fertilizer.
The new facility was designed and built by Stueve Construction, South Dakota. The facility complies with the state's environmental regulations, VanOverschelde says.
The cooperative's personnel work to control the amount of rinse water in the facility. Washing of sprayers, for example, is done in the field to minimize the amount of water collected. The new facility's diking system, which is part of the building's foundation, allows rinse water to flow into sumps. The water is then pumped back into two 3,000-gal. tanks, one for corn herbicides and the other for soybean herbicides.
Fresh water is piped in from the outside, and all of the piping is welded rather than clamped to prevent leaks, VanOverschelde says. The dealership also has tried to make inspection of its liquid tanks easier. PVC pipes with holes in them enable inspectors to dip in sample cups to detect any contamination problems.
MACA also awarded the South Dakota dealership for its environmental safety training programs. Employees are trained in housekeeping, rinse water issues and emergency planning. The dealership benefits from training materials developed by CHS headquarters.
New employees receive “Right to Know” training. The dealership also invites the local fire department once a year to do a walk-through. “We point out the building layout, where the chemicals are and where the no-water zone is. In case of fire, the fire department is not to use water and to let the chemicals burn out,” VanOverschelde says.
Automatic system
Managers of Farmers Elevator & Exchange, Wapello, IA, looked at several area plants for ideas and borrowed the best ones before building a new chemical storage facility in 1995. The southeastern Iowa dealership worked with Bell Consulting, says general manager Greg Greiner.
Greiner also worked with JF Company, which did the engineering work, and Kahler Automation, which installed a computerized mass flow sensor. According to Kahler Automation, mass flow sensors are unaffected by various tank level changes, which is important for companies that have continually changing levels feeding the product pump during a normal day's operation.
Greiner explains that herbicides from the bulk tanks as well as water or nitrogen can be drawn via air valves into the mass flow sensor at 500 gal./min., allowing trucks to be loaded in just about 5 min. Kahler Automation reports that the sensor saves time and labor that normally would be spent checking dispensed product at a platform truck scale.
The automatic system, Greiner says, “cuts down on loading time and tracks everything we do.” Before the dealership had the automated system, one of its employees would have to pump in liquid, then get chemicals ready and mix them in. “We were pumping everything twice. Now we can run as many as six sprayers at a time,” says Greiner, noting that loads are programmed and ready to go in the computer. “Our workload is half what it used to be.”
The dealership now can keep inventories on computer. The computer system also provides a receipt on each load. “If we want, we could eventually bill off this as well,” Greiner says. If the dealership were to receive a complaint about a spraying application, it could call up a particular load on the computer and also check the previous three or four loads to see if there was a problem, Greiner says.
The system is user friendly and safe because the mixer does not come in contact with chemicals. “We used to dump chemicals in jugs. Now the system automatically brings material into the scales, mixes it and injects it right into the line,” Greiner says. The facility also uses an automatic rinse system that eliminates spillage and extra containers. All chemicals are mixed at the plant and hauled to the field. “This way, it's only one person's responsibility to do the mixing,” he says.
The new facility features six 2,000-gal. bulk chemical tanks and six mini-bulk containers. “They can be hooked up to run off the computer as well,” Greiner says. “It helps to have mini-bulk containers when you have smaller amounts of certain materials.” The building also has a separate, elevated storage space for boxed products.
Like its South Dakota neighbor, the Iowa facility is diked to contain spills. “At first, we thought the diking was costly, but now that we have it, there's a night-and-day difference,” Greiner says. “The government probably wouldn't pass a facility today without proper diking.”
Rinse water runs into two pits (one for corn herbicides and the other for soybean products), which can then be pumped into the collection tanks. The dealership does not have to deal with rainwater because everything is inside the building. The building also was built large enough to park four sprayers inside.
Farmers Elevator & Exchange designed the facility with an outside air combustion furnace. Good insulation and a radiant heating system keep the building at above-freezing temperatures.
Like his fellow Water Guardian recipients, Greiner stresses the importance of environmental safety training. His dealership works with Regulatory Consultants Inc. (RCI) to keep pace with environmental regulations and training. Also like its South Dakota neighbor, the Iowa dealership invites the local fire fighters for an annual walk-through and shows them no-water areas.
As these dealers suggest, the construction of environmentally friendly facilities and a commitment to environmental safety have not only helped them to become better environmental stewards but also to improve efficiency and keep pace with changing regulations. As Tony VanOverschelde says, “Water-quality laws will likely only get stricter in the future.” With solid facilities and training in place, these dealerships are poised to handle the changes to come.
2005 Water Guardian Awards
IN ADDITION to Iowa's Farmers Elevator & Exchange and South Dakota's Eastern Farmers Co-op/CHS Inc., three other deserving recipients received the 2005 Water Guardian awards.
Michigan
Harvey Milling Company, Carson City, MI, represented by Mike McCrackin, received its state's 2005 Water Guardian award at the Michigan Agri-Business Association's Winter Conference in Lansing, MI.
The Michigan dealership installed a double dike chemical storage system after a fire in 2003.
The company makes monetary donations to its community and hosts many grower meetings to promote the responsible use of chemicals. During the year, the company has eight interns on site, introducing them to responsible agribusiness.
In addition, Harvey Milling developed the Life Cycle nutrient accounting system for responsibly managing and monitoring nutrients from manure and fertilizer applications.
Missouri
Old Mill Grain & Seed Company, Harrisonville, MO, represented by Ron Osgood and Brian Russell, received its state's 2005 Water Guardian award at the Show Me Ag Classic held at the University of Missouri's Hearnes Center in Columbia, MO.
“Old Mill Grain & Seed Company's dedication to the environment starts at their facilities where they ensure that pesticides and fertilizers are contained and do not leak into the environment,” says Jim Russell, president, Missouri Ag Industries Council. “They practice what they believe and encourage their customers and employees to do the same.”
The Missouri dealership designed its facility to reuse all rain that falls within its containment tank. The facility also is designed to minimize the amount of water that goes off site. Retaining walls prevent pesticides and fertilizers from contaminating the environment.
Each year the company's staff selects environmentally responsible products to recommend based on its customers' watershed needs.
Old Mill annually meets with its local fire department to discuss inventory and how to handle a fire if one were to break out at the dealership.
Nebraska
Helen E. White, Thedford, NE, received her state's 2005 Water Guardian award at the Nebraska Agri-Business Exposition in Omaha, NE. White is the general manager of the Upper Loup Natural Resource District (NRD), which began operating in 1972 as a subdivision of the state government. The NRD focuses on erosion control, water monitoring, tree-planting programs, wildlife management and grazing land management. White works with the University of Nebraska Agronomy Department to carry out these activities.
Every spring, the NRD sells trees for planting projects and has the equipment and expertise to support the planting. The NRD also offers cost-share programs to support and encourage various projects, such as windbreaks, well abandonment and soil testing.
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