Equipment – Spring 2017

A coyple of weeks ago we outlined Pine Island’s spring targets. This week, we spoke with some members of the equipment team for a little more detail on their particular projects!

“We have the sand screener in this week for preventative maintenance,” says team member Coco Mercado. “We’re checking the bearings and greasing everything, putting in a new screen in because there were holes in the old one…we’re fixing anything major so in the field they don’t have problems with it.” This is important, because the sand we use for this project needs to be as pure as possible in order to prevent soil compaction (which can restrict water and limit growth) so we screen it before using it on the barge to take out any clay, stones, or other debris which could cause problems. “Since they got a little ahead with the screening, now’s the perfect time to bring it in,” Coco says. “If we work on it now, when they need it again they don’t have to wait, they can just get moving. We’re just waiting for a few parts to come in and it’ll be back out there!”

Other ongoing shop projects include a revamp of the debris trucks that we use in conjunction with our bog side cleaners.

“We had some issues during the last harvest season because the trucks were getting a little top heavy,” says team member Fred Henschel. “We’re going to knock a foot off to help with that. I’m cutting the original ones apart and making them more like the newer ones with the exposed sides and and painting them all to match. Very similar to the original trucks, but a foot shorter in hopes of them being easier to control; there was so much weight hanging off the back that it grew really difficult for the drivers to steer once the trucks filled up. We’re modifying a couple other little things such as changing the way doors are hinged so if something gets stuck, it’ll be easier to access. Whatever we can do to make it easier, better. And in addition to fixing the original four, we’re building three more brand new ones!”

The next phase in our automation program is also underway just in time for the upcoming frost season! Pump automation has been a boon to our operation. Field data is sent wirelessly to a master controller, which continuously communicates with the network of devices, sending commands to turn on engines and pumps when needed. It gives our team a lot more control: the computer actually handles a lot of the start-up and shut-down process, which is what usually takes up a big chunk of the time an operator is out there running water, either during frost or heat. It also helps us reduce our fuel cost and wear and tear on vehicles as well as protecting that most crucial resource for a cranberry operation: water!

Blog anniversary 2017

Five years ago this week, we launched the Pine Island Cranberry website! While the harvest updates have been by far the most popular (to no one’s surprise!), we are periodically amazed by how many people enjoy the little snapshots of our year, and are always touched by those of you who take the time to tell us so. We are, as always, glad to share with so many people the things we do, how and why we do them, and how much we love it.

Longtime readers of the website are very familiar with Pine Island’s core values, particularly our dedication to continuous improvement: doing everything we do better every day. Among the things we’ve focused on in the past year include working on the next phase of our automation program, improving upon our harvest equipment, working with field experts on our plant nutrition program, and, of course, our ongoing bog renovation! Our team is also exploring new ways to combat the issue of swans in our established beds.

We even added a couple of new features to the blog! A couple of new occasional features we’ve added cover some of the Haines family history as well as a quick look at some of Pine Island’s favorite vendors. We’re proud of our history and our community, and are glad to work with some wonderful companies that have similar goals.

We also did a couple of fun posts around the holidays that will probably become a regular yearly feature: if you missed them, check out what some Pine Island team members were thankful for this year as well as what they wanted for Christmas! (We’re still working on that pink Hydrema.)

And, of course, harvest has both its challenges and triumphs this year, culminating in our second biggest crop ever, and third biggest in terms of barrels per acre! While we remain unavailable for public tours, we did enjoy visits from the agriculture community, as both Ocean Spray and NJ Young Farmers & Ranchers stopped by. We also received some news coverage from Action News, as well as some delicious recipes after a visit from The Rachael Ray Show!

It’s been an enormous pleasure to tell you our story for the past five years, and we are looking forward to another year of achieving our targets, growing our crop, and remaining part of a fantastic ag community! Thank you for following along, and we’ll see you again next week!

Spring Targets – 2017

The weather today is perfect for a blog update on our targets for this spring!

. . . Well, it’s giving us something to look forward to, anyway. Our team is currently finishing up their winter tasks and preparing for the growing season, and so far, things are going well.

“We’ve already taken the water off the beds that are in either their first or second growing season,” says CEO Bill Haines. “We’ve also made good progress this winter on renovation thanks to mild weather, and are hoping to be ahead of schedule so we can begin work on the new renovation project. Sanding is on track; we’ll finish within a week, then start taking water off the established beds as well as start getting irrigation set up and removing swan strings. We’re going to continue to get the dams ready for use of the semis.”

As always, fruit rot is an ongoing concern. “Mike and his team are thinking hard and talking with the scientists at Rutgers and Ocean Spray to see what we can do to better control rot,” Bill says. “We’ve had increased rot for past couple years while standards from the market are higher and higher, so that’s important for us to work on. We’re also looking into improving our equipment; we want to prevent rot altogether, but with either additional equipment or improved equipment we can also try removing rot before delivering to Ocean Spray.” And, of course, our renovation program is expected to assist with this. “We have an entirely new system that we upgraded last year; we’re trying a different layout as well as different sprinkler heads to see if we can improve coverage. We’re also going to work on modifying one of our buggies as a prototype for doing ground coverage as part of rot control.”

“Mainly I’ve been doing a lot of prepwork,” says ICM manager Mike Haines. “Once it gets busier I’d rather not make decisions on the fly; it’s much to have stuff planned out beforehand. So I’ve been spending time with Peter [Oudemans], Dan [Schiffhauer] and Cesar [Rodriguez-Saona] as well as emailing with Joan [Davenport]. We’re mainly thinking about early season applications and putting micronutrients on, specifically copper and zinc. We’re also planning our roughneck fertilizer, which is our first application after micronutrients, basing our decisions on tissue samples, and last year’s yield. For example, everything that got sanded won’t get nitrogen; that sand layer of sand helps decomposition, which in turn increases nitrogen. One interesting thing, looking at tissue samples at Sim Place: the nitrogen levels are higher there, so we’re not making any applications during the roughneck stage. What’s neat about is that we know that the soil is different than at the home farm–it’s much sandier at the home farm–but it’s pretty cool to see that actually reflected in the numbers.”

He’s also working a plan to “culturally” attack the fruit rot issue. “This year we’re gong back to pruning some beds. The hope is that opening up the canopy will lead to a drier canopy and less fruit rot,” Mike says. “We haven’t done it in a few years, though other growers have, so we’re going back to it to see what we can find out.” Other things Mike’s team is working on: Tim Bourgeois is working on getting bees, as well as making sure we’re compliant on safety regulations; Matt Stiles is already working on young beds, replacing some plants that popped out during winter flood; Vanessa DeJesus is going through ICM supplies and making sure we have everything we needed before we kick into high gear.

And, of course, our team is doing the usual ongoing equipment maintenance as well as designing some improvements. “We experimented last year with the dry fertilizer applications on the new buggy,” says COO Bryan vonHahmann. “We learned a lot from that; we discovered it was under-powered, as well as having a few other small issues, so we’re remedying that. We’re also going to be experimenting with using it for liquid applications; it may not be the final unit that we use, but it’s going to teach us a lot. Mike’s working on the criteria for this; we’ll pick one or two systems that will use it exclusively for the entire season and see how we do.” We’re also moving ahead with the next stage of pump automation as well as thinking ahead to harvest. “There are quite a few things we need to do there,” Bryan says. “We’re going to build two more blower tractors, and we’re getting a third bog side cleaner. We’re also going to have some folks come in and talk to us about how to tweak our machinery at the loading platform to try and eliminate rot before sending fruit up to Chatsworth.”

That’s quite a list, but our team, as always, is prepared to work hard and do everything we do better every day!

Pest control: birds

Recently our team has begun looking into some new tech to solve an old problem: swans. Tundra swans migrate to the area every year from Alaska and northwestern Canada and are particularly fond of red root, a weed that competes with cranberry vines for nutrients. When they fly in to feed, they not only tear out the red root, they also tear out vines and leave enormous holes that damage the beds themselves.

Since the swans are a protected species, growers have had to come up with a solution to keep them away from the crop. At Pine Island our PIICM team has been installing swan string for several years. The strings help keep the swans out of the bog by limiting the space available. “Swans are like a commercial airliner,” CEO Bill Haines says. “Having the strings up disrupts their attempt to both land and take off again.” Not all of the bogs are strung; our team maps them out where we have found red root and where the swans have been spotted. Just three acres of swan damage can give us a loss of 200 barrels per acre, or even more, depending on the variety. That takes three years to come back.

Pine Island spends a lot of money and time putting up string every year, and we wanted to find a better solution. “The main issue is getting rid of red root, and renovation helps with that, but that’s not the fastest solution,” says Matt Giberson. So they began to do some research. “We found a laser by Agrilaser that we thought might work, so we contacted them to see if we could demo a unit and they said yes.”

Once it arrived, Louis and Mike helped with the set-up, with Louis working on the power sourcing and Mike working on a plywood stand for the truck. “It’s all set up so we can just put it in the back of a truck and go,” Matt says. “Our first run was Tuesday around 10 A.M. and didn’t see any effect, so I went back to Red Road at dusk.” There weren’t any swans out there, but plenty of geese, and conditions were perfect. “I was surprised how far it goes; from Red Road I could hit the tree line at Ben Haines. I moved it all the way across the reservoir within 100 yards of the geese and they ll took off.” Matt then planned a follow-up evening out at Sim Place, but is feeling pretty confident. “If we can keep them out at night time, this thing could really save us a lot of time that we spend every year setting up and taking down string.”

There are still several tests to run, but so far things are looking great; if all goes well, our swan issue should be greatly reduced!

ACGA Winter Meeting 2017

Yesterday several Pine Island team members attended the annual American Cranberry Growers Association (ACGA) winter meeting. The ACGA winter meeting is always a good opportunity for growers and scientists to listen to research findings from experiments during the previous growing season and the researchers’ recommendations for the 2017 growing season. This year, Pine Island sent Mike Haines, Jeremy Fenstermaker, Matt Stiles, and Tim Bourgeois to hear the latest and greatest!

All four of them were happy with yesterday’s presentations and felt they learned a great deal. Matt Stiles was especially interested in one of the final presentations, from Casey Kennedy of UMass. “Water and underdrain are crucial things for us to get a handle on,” he says. “Casey definitely had some good information in there for us to use, especially to try and get info from everywhere we can and figure out what works best. It had a lot of applicable advice for us.”

Tim Bourgeois was also pleased with the irrigation segment. “I thought the last presentation on irrigation timing, soil conditions, and different flow rates seemed pretty interesting. I’ve been working with Jeremy [Fenstermaker] designing irrigation systems and bog layouts, and we’re already talking about how to minimize our irrigation run times and how to prevent runoff or compaction or flooding in certain areas where we don’t want flooding. And it’s going to be helpful for planting to optimize water use during the growing season.” He also liked Peter Oudemans’ updates on heat stress research. “His crop sensor project is going to get us a lot of useful info once they fine-tune their design,” Tim says. “It’ll be very beneficial to production research and recommendations in the future, because we definitely need to fine-tune what we know and find that perfect balance of enough sunlight, but not too much.”

Jeremy Fenstermaker was pleased to hear from the extension center’s new specialist, Thierry Besançon: “I was excited to hear Thierry’s talk about red root; I’m glad to have some new focus on that. It was nice to meet him and hear some new ideas!”

Mike Haines was also impressed. “I really liked hearing Thierry’s talk; it’s first one I’ve really heard from him, so I liked getting a fresh perspective on the weed problems we have here and how he plans to work on those.” He also paid close attention to the pest talk. “I really liked Cesar’s talk, too; he spoke about two issues I’ve been thinking about a lot: leafhopper and toad bug. There’s still a lot to learn about them, and it was good to hear what researchers have been discovering about the life cycle of these insects we haven’t seen for a while, and how we might deal with them in the future.”

All of our team members in attendance enjoyed the chance to sit down with fellow growers. “It’s always great to see everyone,” Jeremy says. “It’s nice how tightly knit the New Jersey growers community is.”

Special thanks, as well, to Dr. Cesar Rodriguez-Saona, who as always put together a fantastic, well-run program! We appreciate you, Cesar, and we appreciate all of the guest speakers!

Gate construction

While this week’s snowstorm was mild in comparison to last year’s, it still means our team had to suspend our sanding operation and move to other tasks, because our team never stops! Today, some team members shifted to building gates for our latest renovation project. Each year our planned renovations includes the removal of wooden floodgates and replacing them with the newer PVC gate design.

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“Changing to this type of gate was the best thing we’ve ever done,” says one team member. “They’re easier to manage and we get a lot more flexibility of use.”

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Longtime team member Wilfredo Pagan is in charge of this operation. “Pipe gates are better,” he says. “They’re easier to install, and they last longer, too.” First, though, he has to set up the laser level in order to make sure the gate is set up correctly. The team will be able to put the new gate in at the same depth as the old one. This is where they have to be careful; if it’s not even the two parts of the new gate can shift over time since they’re not one solid piece of pipe. “Once you put them together, the only thing holding them is dirt and pressure,” Wilfredo says. “If you have a situation where the canal is deeper than the ditch, you have to measure at the top of the dam and set it so the uprights are level with it. If the canal is lower than bog and you don’t adjust for it, it can wash out underneath.”

In the meantime, Junior Colon has been on the excavator making sure the water’s been blocked off in both the canal and the ditches. “Once that’s blocked off, we can start digging,” he says.

After the water is stopped, it’s time to start digging up the dam. “We go right down to the top of the boards on the old gate,” says Junior, “and then we have to continue to dig behind it to get the turf out and make sure the water’s all gone.”

Once the excavator clears out the dirt around the old gate, it’s time to lift each side one at a time to put the chains on for easier lifting.

The old gate then gets lifted onto a waiting tractor and hauled away.

Once the new gate is installed, the team will fill the dirt back and then haul in turf to patch the sides before crowning the dam and moving on to the next gate!

Winter Flood 2016

The cranberry growing season lasts from April to November; the fruiting buds mature during the winter dormancy period. During the dormant season, severe winter weather could harm or even kill cranberry vines, which is why growers must take preventative measures to protect their crop. When harvest ends, cranberry growers everywhere start their winter flooding. Under normal conditions, the temperature steadily drops post-harvest; it is important to wait until the vines go dormant before starting to put the water on. When vines go dormant, they turn burgundy in color:

Our winter flood program starts with making sure the water in the reservoirs is at the necessary levels. If there has no been significant rain to get the reservoirs to flooding level, we start our wells. We will continue to use the wells to maintain the reservoirs and the stream needed to get the bogs flooded.

The next step is placing boards in the gates to start bringing the water level up in the bogs, much like we do to prep for the flooding at harvest in the fall. The late Bill Sr.’s favorite maxim about just about everything involving cranberries was, “Where is the water coming from, and where do you want it to go?” That can be one of the most challenging things to pick up when you are learning about Pine Island’s system. Manager of Operations Matt Giberson agrees: “There’s a lot to know. How the water works, how to move it the most efficient way. We don’t learn how to do this overnight; I’m still learning new things about it every year.” In practice, this means constant awareness and monitoring of where the water is coming from, where it is going, and how much stream is coming down.

Flooding starts by letting in streams from the reservoirs to canals and bogs. Strategic board placement (more boards in the southernmost bogs to catch the water) will get the ditches high and running down to start flooding from the bottom up.

As the water level in the bogs begins to rise, our team begins adjusting the water level in the bogs by adding boards where they are needed. Once the vines are covered and the stream has settled, we adjust the level of the reservoirs to maintain the stream and keep the bogs flooded for the winter. Wells are shut down once bogs are flooded, and only turned on again if it is dry and reservoir levels are dropping.

It is also necessary to make sure we are not losing water anywhere. “Sometimes you can hear the water coming through a gate that’s supposed to hold it,” Matt says. “It’s the same as running diesel fuel; it’s a big waste, and we need to try to stop it or slow it down.” He does this by adding sand or even grass in front of the leaking boards, as sometimes the sand can wash away too quickly.

Once we are flooded, our team needs to constantly monitor the bogs to make sure there are no leaks, that the water level remains steady, and that the stream remains constant. The weather is also a factor: no rain for a long period of time will shrink the reservoirs and wells may need to be started to maintain the water level in the bogs. Matt says, “If it gets cold enough for the water to freeze, I also need to check to see if I have to break any ice to keep the stream flowing, especially on the southeast gates.”

This year, Jeremy Fenstermaker is training Matt Stiles on the flood process, and Mike Haines continues to learn about it as well. “Both Matt and Mike are getting a handle on what we’re doing as well as understanding why we’re doing it,” Jeremy says. “Mike’s had a couple more years than Matt, but Matt’s learned a lot this year just from running a harvest crew.” He also says communication is everything, because “an action in one section will have a huge effect somewhere else. It’s important to learn the whole process but it’s even more important to know how it all ties together. But Matt and Mike are eager learners and pick things up fast.”

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Once the winter flood is done, our team maintains reservoirs throughout the whole winter. The Ox Pasture reservoir, for example, has to stay high so our team doesn’t have to run the well. This is important because Ox Pasture, situated at the northernmost end of the property, is Pine Island’s largest reservoir and the primary source of water for the home farm.

Putting on the winter flood as quickly and efficiently as possible saves time, fuel, and most importantly, protects next year’s crop. It is this attention to the environment and continuous improvement of our processes that help us grow more acres and more fruit per acre with every successive year.

Sanding 2016

Winter tasks are well underway! The winter flooding has begun, which means that it’s once again time to start sanding.

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Sanding is a fundamental component of our Pine Island Integrated Crop Management (PIICM) program, helping us manage the relationship between water, soil, weather, disease, insects, weeds, and nutrition. Sanding is a process where we apply a thin layer of sand on the bog surface every four years on a rotating basis: one inch for established bogs, a half-inch for young bogs. This procedure helps improve growth and yield by stimulating the development of new uprights (covering the base of the roots strengthens the root system and creates a more healthy vine) while also suppressing disease and reducing insects (by burying weed seed, spores, and insect eggs). It also improves soil drainage while at the same time absorbing and releasing heat so that frost danger in spring is lessened. This increases our efficiency by lowering the need for extra plant nutrition as well as saving water by cutting down frost irrigation times.

The routine usually remains the same every year. First, we check water levels: our team needs to make sure the water is the right depth so our sanding barge doesn’t get stuck on any vines or worse, tear them out. Also, the sand needs to be as pure as possible in order to prevent soil compaction (which can restrict water and limit growth) so we screen our sand before using it on the barge to take out any clay, stones, or other debris which could cause problems.

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Our team begins to prep a couple of days beforehand by checking to see how much the water level needs to come up. The day before the crew arrives, a supervisor will get the water to sanding level (high enough to cover all vines) and measure out the distance the sander will travel. The crew will begin to sand on the deepest side. The water level can then be adjusted if necessary, which helps with dam conservation. They also send the necessary equipment out to the sanding location. A tractor with a winch is on one side of the bog, ready to move the length of the bog; an excavator is on the opposite side of the bog. The cable from the winch is stretched across the bog, through the sander (which has been lifted and put in the bog next to the excavator), and connected to the excavator.

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The process itself is simple: a truck is loaded with sand, then heads over to the bog being sanded, backs up to the excavator, and drops the load into our specially built sandbox (designed to improve efficiency and reduce waste). The excavator operator then loads the hopper of the sander, while the sander operator moves along the cable, adjusting the opening for the sand to fall. The process is repeated, with the excavator and tractor moving forward the length of the bog together.

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This year we’ve targeted over 380 acres for sanding, and over the past year Equipment team members Ernie Waszkiewicz and Coco Mercado have made some modifications which should help the process tremendously. Long time team member Jorge Morales explains: “We made some adjustments so it will move faster; we can probably finish at least an hour to ninety minutes faster than we could last year. New motors, new hoses, new lever, bigger hydraulic tanks, everything brand new. So far, so good; I think we’re going to get a lot more done.”

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We’re betting Jorge is right!

Post harvest clean-up 2016

All of our harvest teams had a strong finish, and now we’re on to cleaning!

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“Cleaning ditches, cleaning excess leaves from bogs, cleaning up everything from harvest. Grass, weeds, debris: all of it,” says COO Byran vonHahmann. “Then once that’s done, we’ll have a crew installing swan string.” Under the direction of Matt Giberson, our foremen are trying out some new equipment to help with some of debris cleanup.

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“We’re trying out some new-to-us equipment that municipalities use for leaf and brush pick-up,” Bryan says. “When we harvest and gather off the same corner of the bog every year, all the leaves come to that corner and settle there. Those are hard to rake out of the vines, and then year after year they settle to the ground. Which means that eventually they’ll choke the vines out and kill them. With some bogs, especially the bigger ones, you end up with a lot and that space becomes significant. So the plan is to vacuum those areas right out. We tested it a couple of weeks ago and it worked really, really well to help us reclaim those corners and keep them healthy.”

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At the same time, the crew is cleaning out the ditches inside the older bogs.

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As far as our other post-harvest project, however: “There’s nothing new with swan string,” Bryan says. “We just have to get it done.”

Tundra swans are a tremendous annoyance to local growers due to their feeding habits. They are particularly fond of red root, a weed that competes with cranberry vines for nutrients. You might think that swans are a natural solution to the problem; unfortunately, when the swans fly in to feed, they not only tear out the red root, they also tear out vines and leave enormous holes that damage the beds themselves.

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Since the swans are a protected species, growers have had to come up with a solution to keep them away from the crop. At Pine Island our team installs swan string. To start, the team places rebar in the ground along the longer sides of a bog, about every 75 feet. On the ends of the bog, the team walks it out and determines how many lines they’ll need to run lengthwise though the center.

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Once the rods are laid out on the dam, a team of three to five people gets into the bog and walks the string across. Once the entire bog is strung, the team goes back in and puts up poles, which are used to keep the strings out of the water so that they don’t freeze. They’re placed in a checkered pattern, not necessarily on every line. The poles can either be cedar posts or recycled irrigation pipe. In addition to the recycling/environmental aspect, reusing the irrigation line is lighter and easier to handle.

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The strings help keep the swans out of the bog by limiting the space available. “Swans are like a commercial airliner,” CEO Bill Haines says. “Having the strings up disrupts their attempt to both land and take off again.” Not all of the bogs are strung; our team maps them out where we have found red root and where the swans have been spotted.

Once all of this is done, our team will be ready for our next targets: sanding and the winter flood!

Harvest’s end – 2016

Harvest finished this week with a bang at Pine Island Cranberry, and we are all proud at what we’ve been able to accomplish this year: 32.6 million pounds of cranberries, with 1,278 acres harvested at an average of 255 barrels per acre!

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“We started slow because we were chasing the color,” says manager Matt Giberson, “but by the end, we had all three teams going seven days a week and we brought in a lot of fruit. On our final three days we were sending over 1.5 million pounds of clean fruit per day to the receiving station, which is a record.” He says the three harvest teams did an incredible job. “It was a safe harvest, too; nobody got hurt. And Matt Stiles did great for his first year as a harvest team leader. His crew started the earliest, and it’s tough to be the guys who are going from early September all the way to the end when the berries just keep coming at you. Long hours, lack of sleep; it all gets to you after a while. But he did a fantastic job.”

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CFO Joann Martin agrees: “24 bogs set records this year! Nadine #3 produced 523 barrels per acre this year, which is amazing.” She also credits the team for this year’s numbers as well as their meticulous attention to detail. “Mike [Guest] always does a great job with tracking the numbers at the packing house, and this year with the two bog side cleaners things are a little different. This was Vanessa’s second year working on the new equipment, and she did a phenomenal job keeping everything straight. Running the trucks out there isn’t always the easiest job but her attention to detail made all the difference.”

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COO Bryan vonHahmann is already looking ahead: “Now that we have the yield results as well as the less fun numbers for things like rot and debris, we can start to build our analysis. We’ll look at what we did bed by bed, comparing it to our application records: what we applied, when, how much. We’ll also look at other activities like weeding, bees, and pollination, then try to determine improvements. For example, if we had one bed that was good but the one immediately next to it was weak, why? How do we improve the weaker bed? It’s a question of taking the large amount of data we have and turning it into something we can manage from, then systematically applying what we’ve learned on bog-by-bog basis.”

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“Obviously we were really happy with the crop,” says CEO Bill Haines. “It was our second biggest crop ever, and third biggest in terms of barrels per acre, so I was really pleased with that. We’re pleased that our strategy of accelerating the renovation of our bogs is working; I think that’s the biggest impact we’ve had. The team worked really hard this year as always, and I’m really proud of the job that they did. And they deserve all of the credit for this crop. We have stuff to work on, and we have to continue to renovate; we had problems with quality and we’re not sure why. It’s probably weather related, but we’re going to work this winter to have a plan to improve on that. But the team did a great job.”

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*Photos courtesy Nadine Haines.