{"id":2120,"date":"2019-04-25T09:31:14","date_gmt":"2019-04-25T13:31:14","guid":{"rendered":"http:\/\/blog.uvm.edu\/cwcallah\/?p=2120"},"modified":"2023-03-10T13:31:40","modified_gmt":"2023-03-10T17:31:40","slug":"last-resort-farm-not-stalled-by-dary-barn-conversion","status":"publish","type":"post","link":"https:\/\/blog.uvm.edu\/cwcallah\/2019\/04\/25\/last-resort-farm-not-stalled-by-dary-barn-conversion\/","title":{"rendered":"Last Resort Farm Not Stalled by Dairy Barn Conversion"},"content":{"rendered":"\n<figure class=\"wp-block-image is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh5.googleusercontent.com\/ltK22Kx0-1KYUqaPUOtlu10TwdFdmxThw9clkVhNkhVYSVIQ3eiuiRwoYrKullkTyRJ6MoRvLKzuF4VxRLbatncDqpEoTfYNwoNLxenTBZ8mETVgJ0cJGOZG5ws3iV6HSLmqrFaM\" alt=\"\" width=\"578\" height=\"324\" \/><figcaption class=\"wp-element-caption\">Silas Doyle-Burr, General Manager of Last Resort Farm<\/figcaption><\/figure>\n\n\n\n<p><em>A PDF of this case study is available for download <a href=\"http:\/\/blog.uvm.edu\/cwcallah\/files\/2019\/05\/UVM-Ext-Last-Resort-Farm-Case-Study-V1.1.pdf\">here<\/a>. <\/em><\/p>\n\n\n\n<p>Silas Doyle-Burr is managing <a href=\"https:\/\/www.lastresortfarm.com\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">Last Resort Farm<\/a> in Monkton, VT, taking over the operations from his parents on the farm he grew up at. The farm was purchased in 1987 and transitioned from dairy farming to vegetable production in 1993. They now grow 26 different crops split just about evenly retail vs. wholesale. <\/p>\n\n\n\n<!--more-->\n\n\n\n<h1 class=\"wp-block-heading\">The Specs:<\/h1>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh4.googleusercontent.com\/LVH63e9wTxkemPi-i-_Q3yRX3KE6S6RIJ-S8d-xdGHPJox_Dd_gfpYuq6catASO5sBczJ8A6MlmdOCufuLAq5EuzZLDt4BRqgPKpbBGcWwYr5MiYDBHUT69SAQDnde92Jgb0ycfc\" alt=\"\" width=\"400\" height=\"225\" \/><figcaption class=\"wp-element-caption\">The previous milking parlor is now the farms retail space, decorated with garlic braids, and various other artwork to make it welcoming.<\/figcaption><\/figure>\n<\/div>\n\n\n<ul class=\"wp-block-list\">\n<li>Location: Monkton, Vermont<\/li>\n\n\n\n<li>Total of 15 acres\n<ul class=\"wp-block-list\">\n<li>10 acres in vegetable and fruit production<\/li>\n\n\n\n<li>5 acre in cover crops each year<\/li>\n\n\n\n<li>90 acres of hay <\/li>\n\n\n\n<li>1,200 Maple taps <\/li>\n<\/ul>\n<\/li>\n\n\n\n<li>USDA Sales Bracket: $100,000-249,999<\/li>\n\n\n\n<li>Crops: Berries and mixed veg, Strawberries and Garlic are the biggest specialties<\/li>\n\n\n\n<li>Markets: Pick-Your-Own, Retail, CSA, farmers market &amp; wholesale <\/li>\n\n\n\n<li>Crew: 4 Full-time &amp; up to 4 part-time Workers (April &#8211; November) , 1 Full-time Worker (December &#8211; March)<\/li>\n\n\n\n<li>Wash\/Pack operation: Dunk tank, barrel washer, triple bay greens washing with DIY Salad spinner, 5 walk-in coolers, (4-CoolBots and 1-split refrigeration)<\/li>\n<\/ul>\n\n\n\n<h1 class=\"wp-block-heading\">About the Project<\/h1>\n\n\n\n<h2 class=\"wp-block-heading\">Overview<\/h2>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh5.googleusercontent.com\/hZnAX_6VdvVvHQR9c7hcguXPvvjveZdXLzq8bElXrbJqsoomYLKfeTb2-xv7P-CRG71N2wlN_W2NFbkwCRRdf4tsJvJTE2iSsyhNDekaJD3o8Ep4qzvqiI-iBlMPWfRTW7RnzBjK\" alt=\"\" width=\"349\" height=\"195\" \/><figcaption class=\"wp-element-caption\">Ceilings are finished with <a href=\"http:\/\/trusscore.ca\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\"Trusscore (opens in a new tab)\">Trusscore<\/a>, covering up existing flaking paint, and enclosing new insulation. Cooler walls painted white, large south facing windows and an \u201copen\u201d floor plan makes for a bright and useful working environment.  <\/figcaption><\/figure>\n<\/div>\n\n\n<p>The area of the barn transformed is 1,950ft\u00b2 which includes 4 new coolers all controlled and monitored by a system set up by <a href=\"https:\/\/www.vecs.org\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">Vermont Energy Control Systems<\/a>.  <br \/><\/p>\n\n\n\n<p>The key features that were a priority for Silas were:<\/p>\n\n\n\n<p>1. <a href=\"http:\/\/blog.uvm.edu\/cwcallah\/2018\/05\/21\/floor-design-for-vegetable-wash-pack-and-storage-areas\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">Slope to drain<\/a>. \u201cBeing able to remove all the wash water immediately and making it easy and convenient.\u201d <\/p>\n\n\n\n<p>2. <a href=\"http:\/\/www.uvm.edu\/vtvegandberry\/factsheets\/Wash_Water_Discharge_Vegetable_Pack_Sheds.pdf\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">Wash water discharge<\/a> management. Having a safe place for wash water to go, and keeping it easy to maintain was an important factor to reduce food safety risk. Cleaning out the sediment trap is a labor intensive job that has to be done periodically when washing heavily loaded crops. <br \/><\/p>\n\n\n\n<p>One goal of the expansion was to increase organization by having dedicated space to store harvest containers, packaging materials or shipping boxes. <\/p>\n\n\n\n<p>This space is large enough to hold frequently used wash equipment including a triple bay sink, &nbsp;greens spinner, smaller dunk tank, and barrel washer all inside, protected from the elements.  <\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh3.googleusercontent.com\/p8qN2W2BuC_UpgSyVLveENat9Cf5FwjFrhT1uj2kfEIAEqkvIOjxrGwvySjyFIDU3zuNY4Y2VIU8cHsxjJTjJVVBBWXklJTX1tAwhur207M4WWNV6J-cbVzAaZTANKeg2NWhr9wq\" alt=\"\" width=\"400\" height=\"225\" \/><figcaption class=\"wp-element-caption\">A custom DIY rack for drying and storing totes. Both the rack and the barrel washer on wheels for flexibility and easy mobility. <\/figcaption><\/figure>\n<\/div>\n\n\n<h2 class=\"wp-block-heading\">Flow<\/h2>\n\n\n\n<p>Silas had intentional flow in mind at the start of the project. He wanted a space where product comes in at one end (gets cleaned, packed, stored) and is delivered out the other. The addition of a loading dock provides the ability to move pallets and pallet bins of product which was not possible before. &nbsp;&nbsp;<br \/><\/p>\n\n\n\n<p>The improved flow design has, indeed, reduced labor costs. It used to take &nbsp;45 minutes to set up up the barrel washer to clean a batch of roots. Now, having space, they can just roll it over and be ready to go in just a couple minutes. <\/p>\n\n\n\n<figure class=\"wp-block-image\"><img decoding=\"async\" src=\"https:\/\/lh4.googleusercontent.com\/bPxsupYY4kKki2KXmF3jRseB5LTzHkANh4Xv0PAk8ZuZTUS0FMiA4vG3vseBT_Cmc8Jko3l32rID70wJ6WL7dl3o-IzlbJFJQKGo71_QYOGlPgCnjSgxthIig_nwdIIlXQpoSCkq\" alt=\"\" \/><figcaption class=\"wp-element-caption\">This floor plan shows the basic layout and use of about half of the barn use for vegetable washing, packing and storing.  <\/figcaption><\/figure>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p>\u201cIt\u2019s more of the entire system in itself that will be the major cost saver for us.\u201d <\/p>\n<\/blockquote>\n\n\n\n<h2 class=\"wp-block-heading\">The Why<\/h2>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh3.googleusercontent.com\/AH3LhhZqWx4GDfnvrYPF4P-ymeIFmLn66PmPYw7IkV6lnNwOV-W-bVT1b9VDtrKfrKwMe0Kecuz3nBezOsB75kuvmsEZUTLGIbtLf34Zg4PRMn1Q2d9uUx3PJ3ssZYexk3vQ9DWF\" alt=\"\" width=\"400\" height=\"225\" \/><figcaption class=\"wp-element-caption\">This cooler is equipped with a commercial split refrigeration system and used when there needs to be a lot of field heat removed quickly. Shelves are in the plan, but organization can still be made temporarily with masking tape. <\/figcaption><\/figure>\n<\/div>\n\n\n<p> There were a several motivations for this renovation. Primarily, increasing efficiency and ease of production and retail sales by separating the washing and packing from the farm stand. Secondly, Silas wanted to improve the produce safety practices on the farm. Additionally, insulating, heating, and expanding the working space into a larger area of the barn enabled work to be more feasible and comfortable without worrying about freezing conditions bursting pipes or damaging stored crops. This conditioned space has extended the  shoulder season greens production later into the fall due to increased ease of washing. <br \/><\/p>\n\n\n\n<p>The renovation has allowed growth of the business. Even with a few remaining kinks still to be worked out, a 15% increase of sales has been gained from expanding the cooler capacity. The additional space allows more crops to be stored and sold into the winter and even the next spring. &nbsp;<br \/><\/p>\n\n\n\n<p>This conditioned space also now adds the ability to increase new, specialty crop production like sprouting ginger and turmeric. <\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh4.googleusercontent.com\/bblv3eH9YNAH7I97E8GpqQp7vRAFHhDq02Ygv1dTHLrobOUD4VyRkDwg1hNG1C4PpALcj2XFS_yyvCxg4C_fIWrG4c2_Pd3WIaDizkgHOP3PMsNcr1rOtLhnui_h8W00kY5wuLQw\" alt=\"\" width=\"312\" height=\"234\" \/><figcaption class=\"wp-element-caption\">The renovations included installing a covered loading dock, with a dock leveler. This enables easy wholesale transactions and adds additional outdoor covered storage. <\/figcaption><\/figure>\n<\/div>\n\n\n<h2 class=\"wp-block-heading\">Cost<\/h2>\n\n\n\n<p>The cost of the project totaled up to ~$60,000 which included chiseling out concrete, fixing drainage, building 4 new coolers, insulating, instrumenting (temp and humidity controls for coolers), and building a covered loading dock. <\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Best Decisions<\/h2>\n\n\n\n<p>A \u201cgutter\u201d style trench drain and floors pitched to it. Using a 2% slope, water and debris easily find their way to the gutter which can be cleaned out on a routine basis. \u201cI think that that\u2019s actually the most important feature that we have here,\u201d noted Silas pointing to the drain.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh4.googleusercontent.com\/OFW7Td5arQ6gbndzOzZm6NHQQnLUbh_Uj8oYYLeL6Uu9yXKL4QxGFwBTrt4mZyTGcbgZtTo-DjKSKieg0HHJUihgbzhlZQIrD5z-85CH5JSXc9g39aUPpoDEwGXWdyZ3zJ1Cw4OV\" alt=\"\" width=\"400\" height=\"225\" \/><figcaption class=\"wp-element-caption\">Silas utilized the existing gutter of the dairy barn. For wash water catchment. Some chiseling\/grading and installation of a clean-out was needed to trap the sediment. <\/figcaption><\/figure>\n<\/div>\n\n\n<p>Another key feature was cleanability. Installing smooth cleanable surfaces allows the space to be cleaned well on a regular basis. He used <a href=\"https:\/\/trusscore.ca\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">Trusscore<\/a> as a finish material on inside walls. &nbsp;This is easy to install and doesn&#8217;t require any sheathing behind it. It\u2019s not cheap but Silas worked the numbers and noted, \u201cBased on labor savings it seemed to come up on top.\u201d <br \/><\/p>\n\n\n\n<p>Installing casters on the main equipment (tables, barrel washer, greens spinner) makes the set-up of different jobs in the wash-pack space quick and easy to transition between crops. <\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Concerns <\/h2>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/lh3.googleusercontent.com\/YZ0JMsDFSA8uigVk3M6ygL1446YVshX2Tn3_zaLfqMaPMRpnUei5VEEuGEg29_SP-DzC1g4UElT8Ced4yn0xBqaxqPQRcB4hqc1fRAtz1SS-u3Qsbbv_SKFDatuIuhSbpeUjedke\" alt=\"\" width=\"334\" height=\"187\" \/><figcaption class=\"wp-element-caption\">The DewRight Humidity sensor accurately measures and reports the relative humidity to a computer which controls humidifiers to optimize storage conditions to  ideal set points for storage crops. <\/figcaption><\/figure>\n<\/div>\n\n\n<p>\u201cRetrofitting into the dairy barn does have its challenges and so there was a lot of labor on our end that factors into that cost,\u201d Silas reflected. Examples include breaking up existing concrete, figuring out the best ways to insulate, and the management of water were all challenges that had to be faced. Some of these challenges may not have been as difficult if this was a new construction project from the start. <br \/><\/p>\n\n\n\n<p> Another concern is the longevity of the custom-built coolers. In such highhumidity conditions. moisture management and condensation are key considerations. The use of smooth and cleanable finish materials and vapor barrier behind them helps to manage this challenge.  <br \/><\/p>\n\n\n\n<p>Silas also noted how he can see within a couple of years he may be outgrowing the space and begin to wish he planned for a larger space from the start. <\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Contributors to the project <\/h2>\n\n\n\n<p><a href=\"http:\/\/go.uvm.edu\/ageng\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">UVM Extension Ag Engineering<\/a> and <a rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\" href=\"mailto:producesafety@uvm.edu\" target=\"_blank\">Produce Safety Team<\/a> &nbsp;<\/p>\n\n\n\n<p><a href=\"http:\/\/blog.uvm.edu\/farmvia\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">UVM Extension Farm Viability<\/a> and <a rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\" href=\"https:\/\/www.richardwiswall.com\/\" target=\"_blank\">Richard Wiswall<\/a><\/p>\n\n\n\n<p><a href=\"https:\/\/agriculture.vermont.gov\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\">Vermont Agency of Agriculture<\/a> &nbsp;through the <a rel=\"noreferrer noopener\" aria-label=\" (opens in a new tab)\" href=\"https:\/\/agriculture.vermont.gov\/producesafetygrants\" target=\"_blank\">VT Produce Safety Improvement Grant<\/a> <br \/><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Watch a video about the project<\/h2>\n\n\n\n<figure class=\"wp-block-embed is-type-video is-provider-youtube wp-block-embed-youtube wp-embed-aspect-16-9 wp-has-aspect-ratio\"><div class=\"wp-block-embed__wrapper\">\n<iframe loading=\"lazy\" title=\"Last Resort Farm: Post Harvest Case Study\" width=\"640\" height=\"360\" src=\"https:\/\/www.youtube.com\/embed\/videoseries?list=PLRhtZw1o6RdFOSoR3QriKs3i3njkEYezi\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" referrerpolicy=\"strict-origin-when-cross-origin\" allowfullscreen><\/iframe>\n<\/div><figcaption class=\"wp-element-caption\">To watch an interview with Silas about this project in this <a href=\"https:\/\/youtube.com\/playlist?list=PLRhtZw1o6RdFOSoR3QriKs3i3njkEYezi\" target=\"_blank\" rel=\"noreferrer noopener\">playlist<\/a>. <\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Share This Post!<\/h2>\n\n\n\n<p><a href=\"https:\/\/go.uvm.edu\/lrf\" target=\"_blank\" rel=\"noreferrer noopener\">https:\/\/go.uvm.edu\/lrf<\/a><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Looking for more Post Harvest Case Studies? <\/h2>\n\n\n\n<p>We showcase several farms of various sizes, features and budgets in this series. Visit: <a href=\"http:\/\/go.uvm.edu\/phcs\" target=\"_blank\" rel=\"noreferrer noopener\">go.uvm.edu\/phcs<\/a><\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Acknowledgments <\/h2>\n\n\n\n<p><em>This case study is possible because of the hard work, wisdom, and generosity of Silas Doyle-Burr and his family at Last Resort Farm. Without their willingness to take the project on to begin with, deal with all the challenges that such projects bring, and complete it we would have nothing to share.  We are grateful to them for their willingness to share their story and knowledge in this form so that others can learn.<\/em><\/p>\n\n\n\n<p><em>Funding for this publication was made possible, in part, the USDA Northeast Sustainable Agriculture Research and Education program through award LNE19-375, by the Food and Drug Administration through grant PAR-16-137, by the USDA\u2019s National Institute of Food and Agriculture through the Food Safety Outreach Program award 2016-70020-25792 accession 1010528 and by The Vermont Agency of Agriculture Food and Markets via the Integrated Extension Educational Programming in Support of the VAAFM Produce Program Grant 02200-FSMA-2018-01. The views expressed in the publication do not necessarily reflect the official policies of the U.S. Department of Health and Human Services, the U.S. Department of Agriculture or the Vermont Agency of Agriculture; nor does any mention of trade names, commercial practices, or organization imply endorsement by the United States Government or the State of Vermont.  <\/em><\/p>\n","protected":false},"excerpt":{"rendered":"<p>A PDF of this case study is available for download here. Silas Doyle-Burr is managing Last Resort Farm in Monkton, VT, taking over the operations from his parents on the farm he grew up at. The farm was purchased in 1987 and transitioned from dairy farming to vegetable production in 1993. They now grow 26 &hellip; <\/p>\n<p class=\"link-more\"><a href=\"https:\/\/blog.uvm.edu\/cwcallah\/2019\/04\/25\/last-resort-farm-not-stalled-by-dary-barn-conversion\/\" class=\"more-link\">Continue reading<span class=\"screen-reader-text\"> &#8220;Last Resort Farm Not Stalled by Dairy Barn Conversion&#8221;<\/span><\/a><\/p>\n","protected":false},"author":4505,"featured_media":4600,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"footnotes":""},"categories":[523959,50616,43530],"tags":[523955,20145,524022,6521,262721,523999,523927],"class_list":["post-2120","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-case-studies","category-refrigeration-and-storage","category-washing-and-packing","tag-barn","tag-food-safety","tag-last-resort-farm","tag-post-harvest","tag-produce-safety","tag-silas","tag-wash-pack","entry"],"featured_image_src":"https:\/\/blog.uvm.edu\/cwcallah\/files\/2019\/04\/IMG_7902-1-600x400.jpg","featured_image_src_square":"https:\/\/blog.uvm.edu\/cwcallah\/files\/2019\/04\/IMG_7902-1-600x600.jpg","author_info":{"display_name":"Andy","author_link":"https:\/\/blog.uvm.edu\/cwcallah\/author\/achambe4\/"},"_links":{"self":[{"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/posts\/2120","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/users\/4505"}],"replies":[{"embeddable":true,"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/comments?post=2120"}],"version-history":[{"count":18,"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/posts\/2120\/revisions"}],"predecessor-version":[{"id":5547,"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/posts\/2120\/revisions\/5547"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/media\/4600"}],"wp:attachment":[{"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/media?parent=2120"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/categories?post=2120"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/blog.uvm.edu\/cwcallah\/wp-json\/wp\/v2\/tags?post=2120"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}