0 I I
Pea Freezing Operations
Part I.—Vining
G. B. Davis
H. M. Hutchings
Miscellaneous Paper 66
January 1959
Agricultural Experiment Station, Oregon State College, Corvallis
in cooperation with
Agricultural Marketing Service, United States Department of Agriculture
FOREWORD
This report is the first of a series of publications dealing with
costs and efficiencies in pea-freezing plant operations. The others will
be concerned with freezing, storing, and packaging.
These studies are being made under a regional research project concerned with the marketing of frozen fruits and vegetables. The Experiment
Stations of Oregon, Washington, California, Hawaii, and the Agricultural
Marketing Service, U. S. Department of Agriculture are co-operating in
this program.
INTRODUCTION
Vining of green peas is an operation that uses large amounts of labor
and equipment. Cost of vining is a substantial portion of the total cost
of operating a pea-freezing plant. This report is concerned with an analysis of vining costs as they relate to different methods being used in the
Northwest frozen-pea industry.
Processing costs have risen sharply in recent years, and many of
these costs are beyond control of the packer. The cost of transporting
the frozen product, materials and supplies, is one example. This is especially important because the Pacific Northwest produces about 70% of the
frozen peas marketed nationally. Competing areas are closer to major
markets and have a distinct advantage in lower transportation costs and
lower wage rates.
The frozen-pea industry in the Northwest has viewed these rising costs
with concern and has been extremely alert in making changes in their operation that will permit cost reduction. This report concerning vining operations and others soon to be published dealing with costs and efficiencies
in freezing, storing, and packaging are intended to provide the industry
with information that can be used as a basis for making decisions for further
improvements in efficiency.
The vining operations analyzed in this report are field vining and
plant vining. Both are common methods currently being used in the Northwest.
In field vining, viners are portable and are set up in or close to the fields
being harvested. After harvest viners are moved by truck to the next harvesting location. The vines are seldom hauled more than two or three miles
to the portable vining station. After the peas have been shelled, they are
hauled in lug boxes to the freezing plant. There they are unloaded, dumped,
and the empty lugs washed and returned to the vining station.
Plant vining involves the same general operations except that the viners
are located permanently at the freezing plant. Permanence of location permits
the use of labor-saving equipment, which will be discussed later. Vines are
hauled from fields located mostly within a 20-mile radius of the plant. The
shelled peas are moved by flume, belt, or are pumped to the processing plant
from the vining station.
A method of vining only recently introduced into the Oregon pea industry
is not included in this report. This method will be studied in the near future
and its costs and relative efficiency will be compared to plant and field
vining. This method utilizes permanent field-vining stations located close
to pea production centers. It appears to have some advantages over both plant
and field vining. It has most of the labor-saving equipment of plant vining and
the relatively short distances for hauling vines as in field vining. Also the
shelled peas are hauled to the freezing plant in bin or pallet boxes instead of
the lug boxes normally used in field vining.
In the following report the costs of plant and field vining are compared
on the basis of
(1) distance from fields to freezing plants
2
(2) scale of operation -- output of clean peas per hour
(3) pea-vine ratio.
The results are shown first, and the methods used in computing the
costs are, shown in a later section.
RESULTS
Plant vining offers substantial economies over field vining at all
distances and for all plant volumes studied (figure 1). A plant with an
operating capacity of 20,000 pounds of clean peas per hour can vine at the
plant for an estimated total seasonal cost of about $250,000 when hauling
an average distance of five miles. Total field-vining costs are estimated
to be $355,000 for the same distance and plant volume. This differential
in total cost narrows as distance from field to plant increases -- plantvining costs increasing much more rapidly than field-vining costs. At 20
miles, annual costs favor plant vining by only $33,000 as compared to
$105,000 at five miles. At a distance of 25 to 30 miles, costs for the two
methods are approximately the same. This relationship holds true for the
other plant volumes and distances considered when costs are computed on a
unit basis -- costs per hundredweight of clean peas (figure 2).
The distances and plant volumes used in the illustrations are typical
of current pea-freezing and canning operations in the Pacific Northwest.
The costs cited, however, are not averages of individual plant operations.
They are based upon labor and equipment standards of performance developed
for the different jobs making up the vining operation. These standards were
determined through time and production studies, plant record data and equip,
ment manufacturers' specifications. In general, performance standards of
labor and equipment were selected that were above average, but well within
the capacity of the crew and equipment.
Costs take into account all operations beginning with loading vines in
the field through clipper cleaning at the freezing plant. Costs include
those for labor -- both direct and supervisory -- equipment, facilities, maintenance and repairs, depreciation, taxes, insurance, interest on investment,
and operating items such as fuel and power. Costs of placing vines in pits
is included but no credit is allowed for their value. Overhead expenses at
the management level, including the office force and fieldmen, have been excluded.
As distance from the plant increases, hauling costs increase much more
rapidly for plant vining than for field vining. This is shown in figures 1,
2 and table 1. An increase of one mile in the season's average distance
adds over three cents per hundredweight of clean peas to the costs of plant
vining, but only slightly more than one cent to field vining. For a 20,000
pound an hour plant-vining operation, an additional vine truck and driver is
required for each increase of about two-thirds of a mile. Field vining has
constant vine-truck requirements and only a slight increase in lug-box trucks
and drivers as distance increases. (See table 6 for crew organization.)
Figure 1. Vining Costs as Related to Method of Vining, Distance of Field
from Plant, and Volume of Peas Vined per Hour, Oregon 1957 Crop
Year./1
Thousand
dollars
600–
Field vining
Plant vining
30,000 lbs.
per hour
550
500
450
400
4.$
20,000'lbs,
per hour
•••••
.••n•
O
• 350
'-4
• 300
O
O 250
10,000 lbs.
per hour
200
150
5,000 lbs.
per hour
100
50
10
15
Average distance--miles one.
20
field to plant.
/1 Assumes the following:
a. A 1000-hour operating season.
b. A distance of 2 miles from the field to the field vining station.
c. A pea-vine ratio of 20 percent.
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At some point between 10 and 15 miles, hauling costs for the plant
vining operation exceed the hauling costs of field vining. The plant-vining
operation, however, has other costs that continue to be lower than for field
vining irrespective of distance. For example, the crew engaged only in the
actual vining consists of 67 persons for a field-vining operation of 20,000
pounds an hour capacity. Only 40 persons are required for a plant operation
of the same size. This economy in labor in the plant operation is made possible by the use of electric forks, feed regulators, and conveyor belts to
move the shelled peas from the viners. This equipment normally is not employed by the portable field viners.
The feed regulator and electric fork reduce labor requirements. Also
the output of clean peas per viner-hour was 720 pounds for field vining and
800 for plant vining. This rate of output, of course, will vary depending
on the pea-vine ratio (percentage clean peas are of total pea and vine
weights), weed content, and other characteristics of the vines.
The conveyor system of the plant operation replaces one off-bearer required for each field viner. Together the feed regulator, electric fork,
and conveyor belt eliminate three out of four workers for each set of two
viners.
Another point where field vining uses more labor is the receiving
platform at the freezing plant. .A freezing plant with a capacity of 20,000
pounds of clean peas per hour requires about 15 persons for receiving and
dumping filled lugs and cleaning and loading the empties. This operation
does not exist in plant vining. Also the cost of moving viners from one
field station to another does not occur in plant vining.
Lower costs per unit of product result from each increase in vining
capacity for both methods (table 2). The largest gain in economy is achieved
in moving from the 5,000-pound level of capacity per hour to the 10,000pound level. Vining costs are reduced by 27 cents per hundredweight for
this interval in plant vining and 37 cents for field vining. At capacities
greater than 10,000 pounds per hour, additional economies shrink so that
between 20,000 and 30,000 pounds per hour costs decrease by only five to six
cents per hundredweight for the two methods.
These economies are made possible by the more efficient use of both
labor and equipment. In the smaller operations, the full capacities of the
labor and equipment are not being utilized. For example, a small-scale
operation requires the use of vine-spreading equipment in the silage pit,
truck scales, lug-box dumping and washing equipment, and the labor to supervise and operate this equipment. Plant capacity could be increased with
little or no change in this equipment and labor.
Higher pea-vine ratios result in lower vining costs (table 3). When
the percentage of clean peas per unit of vines is increased, the output of
clean peas per man-hour is increased for jobs such as loading, hauling, and
pitching. If the pea-vine ratio is 15%, the estimated total vining cost per
hundredweight of clean peas is $1.82 for plant vining and $2.30 for field
vining. If the percentage were 25 instead of 15, the cost per hundredweight
would be $1.16 and $1.64, respectively. Costs are reduced because fewer
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vines are handled for each hundredweight of clean peas.
Although the grower and processor have little control over the pea-vine
ratio, it is important to point out that vining costs are very sensitive to
this ratio. This effect on cost also suggests an area for possible future
research directed toward the reduction of the quantity: of vines which must.
be handled per unit of clean peas.
BASIS FOR ESTIMATING COSTS
In the cost estimates cited earlier, it has been assumed that the
vining season extends for 1,000 hours of operation at capacity. Individual
processing plants may have a season that exceeds or is less than this period.
Plant records for these operations, however, indicate that this is a reasonable-season considering the climate and growing conditions required by the
crop in the Northwest.
Labor
Estimated costs for labor are based upon (1) typical wage rates and (2)
production standards for the different jobs making up the vining operation.
These standards were developed from time and production studies of indivi
dual crew operations (table 4). They have been used to compute the estimated size crew needed for specific jobs. For example, the time studies
indicate that if 10,000 pounds of clean peas are to be delivered to the
freezing plant, four loader-operators would be required. This is based on ,
time study results that show a loader's, somewhat better than average, output
is 2,500 pounds of clean peas per man-hour. The 10,000 when divided by
2,500 gives a crew of four operators. Additional labor for field-loading
crews consisting of hand pitchers, field foremen, and loader mechanics is
calculated in a similar manner. An allowance of 20% for delays and rest
periods has been included.
Using the same procedure and a 10,000-pound hourly output, 7 vine
pitchers for plant vining and 28 pitchers and off-bearers for field vining
were calculated as the crew requirements for these two methods. The output
of clean peas per man-hour was 1,600 pounds for plant vining and 360 for field
vining. Other personnel making up the vining-station crew would be estimated from the standards.
Wage rates established for particular jobs for both plant and field
vining are shown below. Electric fork operator's wages are not shown since
they were paid on a piece rate. In the cost calculations these wages have
been increased by 6% for social security and other employer costs.
Job
Foremen
Clipper cleaner and "cat"
operators and mechanics All other jobs
Wage per hour
$1.75
1.50
1.25
10
Table 4. Labor Standards for Vining Green Peas, Oregon, 1957 Crop
Year. LI
Job
Loading in the field
Loader mechanic
Field clean up
Field foreman
Vining
Viner clean up
"Cat" and tractor operation
Viner mechanic
Vining station supervision
Hand truck lugs to dumper
Dump-lug boxes
Wash-lug boxes
Receiving dock clean up
Receiving foreman
Truck weighing
Sample grading
Clipper cleaning
Truck spotter
Truck dispatcher
Method of Vining
: Plant Vining
:
Field Vining
(pounds clean peas per man-hour)
2,500
2,500
5,000
5,000
10,917
10,917
30,000
30,000
1,600
360
3,200
15,000
10,000
3,200
2,885
7,500
10,000
11,599
7,902
11,554
15,000
30,000
30,000
30,000
30,000
30,000
7,500
7,500
30,000
30,000
WO 00
00 MP
III 00
Oa.*
MO 00
/1 Includes an allowance for normal delay and periods of downtime.
Equipment
These costs consist of annual fixed charges' and variable costs including repairs, maintenance, and power. The annual fixed charge is composed of
depreciation based on the estimated years of useful life; insurance, taxes,
interest; and a sum for fixed repairs. These costs for the different pieces
of equipment are shown in table 5.
Variable repairs and maintenance are computed on the basis of 1,000
hours of use. This amounts to 57. of the replacement plus installation cost
for most items of equipment.
Electricity and fuel consumption for motors was calculated from manufacturers' specifications, results of tractor tests, and other published
material. Pricing used on a delivered basis amounted to 15.9 cents per gallon for diesel fuel, 27.9 cents for gasoline, 95 cents per gallon for lubricating oil, and 17 cents per pound for grease. Electricity rates amounted
to 8.7 mills per KWH for plant operations.
The estimated number of pieces of equipment required for the different
rates of output is based upon the equipment standards developed from time
and production standards and from manufacturers' specifications. Time and
production studies showed that a field viner's output with pea-vine ratio of
20% was approximately 720 pounds per viner-hour. An output of 10,000 pounds
of clean peas per hour would require 14 viners (10,000 pounds divided by 720
pounds).
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