Hops Feasibility Study PDF

20092010FeasibilityandMarketResearchStudy
For
CommercialHopProductioninNewEngland
September30,2010
Four Star Farms hopyard, photo credit: r.wilson
Preparedby
RosalieJ.WilsonBusinessDevelopmentServices
rosaliewilson.com
Withfundingfrom:
VermontAgencyofAgriculture,Food,andMarkets
MassachusettsDepartmentofAgriculturalResources
Page1
TableofContents
ExecutiveSummary............................................................................................................. 2
Background ......................................................................................................................... 3
Methodology....................................................................................................................... 6
Initialfindings...................................................................................................................... 7
MarketResearchSurveyDetails ....................................................................................... 10
ProductionFeasibility ....................................................................................................... 18
OtherIssuesAffectingGrowingCapabilityandCommercialProduction......................... 24
Conclusions ....................................................................................................................... 35
NextSteps ......................................................................................................................... 42
AppendixASourcesofInformation
AppendixBListofPersonsConsulted
AppendixCBrewerQuestionnaireTemplate
AppendixDCashFlowScenarios
AppendixESampleHopyardDesigns
AppendixFHopyardEstablishmentCostsPerAcre
AppendixGLaboratoryAnalysisServiceProviders
AppendixHExpiredHopHarvesterPatents
AppendixIFujiImpulseNitrogenFlushVacuumSealerProductInformation
CommercialFeasibilityofLocalHops
2010
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ExecutiveSummary
TheVermontAgencyofAgricultureFoodandMarketsandtheMassachusetts
DepartmentofAgriculturalResourcescommissionedthisresearchprojecttostudythe
economicandlogisticfeasibilityofcommercialhopproductioninNewEngland.The
goalistoexpandopportunitiesforNewEnglandgrowerstogenerateaprofitable
incomefromtheirland.Thisreporthasdeterminedthatisfeasibletogrowa
commercialhopcropinNewEngland:
A. Thereissufficientdemandfromthebrewingcommunitytosupportaminimum
of100acresinproduction.
B. Thereissufficientpricepointelasticitytoaffordproducersanabilitytogenerate
aprofit,andareasonabletimeframeforreturnoninvestment.
C. Theinformation,technology,andequipmentnowexistforsmallerscale,110
acrecommercialhopoperations.
D. Asidefrompotentiallimitationsoftopsoildepthtobedrock,NewEnglands
growingclimateandconditionsarewellsuitedtohopproduction.
Thefourscenariosinwhichagrowercouldyieldapositivenetincomefromgrowing
hopsareasfollows:
Scenario1:
ParticipatinginavaluesharegrowingprogramwithAtlanticHops
Scenario2:
Sellingwholehops,minimallyprocesseddirecttobrewers
Scenario3:
UsingAtlanticHopsforprocessingservicesandsellingpelletized
hopsdirecttobrewers
Scenario4:
Sellingdoityourselfpelletizedhopsdirecttobrewers
IncomePotentialandReturnOnInvestment
AverageYield
PerAcre
AverageNet
IncomePer
Acre
AverageReturn
OnInvestment
for1stAcre
Levelof
IndividualRisk
Scenario1
1,500driedlbs
Scenario2
1,500driedlbs
Scenario3
1,500driedlbs
Scenario4
1,500driedlbs
$4,640
$5,090
$5,090
$12,910
5years
5years
6years
4years
Low
Moderate
Moderate
High
assuminga$10/lbpricepointforwholedriedhops,$15/lbforpelletizedhops,and$9/lbreturnfromthe
valueshareprogram
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Whilethepotentialtogeneratenetincomeperacreishighestinscenariofour,inwhich
thegrowercreatesthevalueaddedfinishedproductonsite,theultimate
recommendationistoadoptscenarioone,inwhichgrowersparticipateinavalueshare
growingprogramwithAtlanticHops.Thisisbecausescenarioonerepresentstheleast
riskwhilestillpresentingastrongpotentialforfinancialreturn.
Inallinstances,inordertoreachareasonableincomeandrateofreturnoninvestment,
acommercialgrowerwillneedtoutilizemechanicalharvestingandsorting.Inorderto
minimizeriskfromcropfailure,andtostaggerharvesttimesforlogisticalease,itis
highlyrecommendedthatthegroweralsodividethehopyardintothirdsandadopta3
varietyplanting.
Background
NewEnglandwashometoavibranthoptradethroughthebeginningoftheTwentieth
Century.Infactin1900,NewYorkwasthelargestproducerofAmericanhops,
generating49%oftheentireU.S.yield.BytheendofProhibition,however,muchof
thehopindustryhadmigratedtothePacificNorthwest.Thiswasduetoadvancesin
mechanizationthatmadelargerscalefarmingareality,complementingWestCoast
geography,andthedecimationoftheEasterncropsbyadiseaseknownasdowny
mildew.Downymildewisacripplingdiseasebecauseitcancauseshortandlongterm
damage,impactingaspecificyearsharvest,andpotentiallykillingtheplants
themselves.1Thepotentialtokilltheplantisasignificantissuewithacropsuchas
hops,becausetheyareaperennialplantandtakethreetofouryearstoestablish.
WhyisthereaninterestinthecommercialviabilityofgrowingNewEnglandhops,and
whynow?
1. Thebeerindustryisamatureindustrywithdemonstratedlongevityandstable
consumption.Thistranslatesintostablemarketdemandforrawingredients
suchashops.Eveninthemidstofoneoftheworstrecessionsinhistory,2009
U.S.beersalesonlydecreased2.2%.2
2. Inthe1970sasegmentofthebrewingindustry,craftbrewing,begantodevelop
popularityintheNortheast,particularlyinNewEnglandandQuebec.Craft
brewers,originallyconsideredfringe,arenowacceptedinthemainstreambeer
Barth,H.J.,Klinke,C.,Schmidt,C.TheHopAtlas.1994.Nuremberg,Germany.Joh,Barth&Sohn.pp12
14.
JasonPerrault.PerraultFarms.GuestSpeaker.2010WinterHopsConference.UVMExtension.
3/26/2010.
2
http://www.brewersassociation.org/pages/businesstools/craftbrewingstatistics/facts
2010
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3
industryandmakeup5%ofthetotalUSbeermarketshare. Notonlydoesthe
categorynowmakeuparespectableshareofoverallbeersales,itcontinuesto
riseastheshiftinconsumptiontrendsawayfromconsumingvolumequantities
ofmassmarketed,lowcostbeer,toselective,smallerquantitiesofhigher
qualityproducts.4
A2007reportexpressedthistrendasfollows:
TheBrewersAssociation,thetradeassociationthattabulatesindustrydatafor
craftbrewers,reportscraftbeersalesandgrowthcontinuetobreakrecords.
Thevolumeofcraftbeersoldinthefirsthalfof2007rose11%comparedtothis
sameperiodin2006anddollargrowthincreased14%.Forthefirsttimeever
craftbeerhasexceededmorethana5%dollarshareoftotalbeersales.
Overall,theU.S.beerindustrysoldonemillionmorebarrelsinthefirsthalfof
2007comparedto2006,with400,000ofthesenewbarrelsproducedbycraft
breweries.Thisequatesto3.768millionbarrelsofcraftbeersoldinthefirsttwo
quartersof2007comparedto3.368millionbarrelssoldinthefirsthalfof2006.
ScandatafromInformationResources,Inc.provideadditionaldatapointsthat
confirmstrengthforthesegment.Craftbeersalesinthesupermarketchannel
throughJuly15,2007showeda17.4%increaseindollarsalescomparedtothe
sameperiodin2006.Thisgrowthinsaleswashigherthananyotheralcohol
beveragecategory.
"The1,400small,independentandtraditionalcraftbrewersintheU.S.havehit
theirstride,"saidPaulGatza,DirectoroftheBrewersAssociation."United
Statescraftbrewersaremakingmanyoftheworld'sbestbeers,andthe
marketplaceisresponding."
Coupledwiththegrowthstatisticshasbeenatidalwaveofmediacoveragein
thefirsthalfof2007includingNBC'sTodayShowonJuly3stating,"Beeristhe
newwineandcangowithjustaboutanyfood."Additionally,Gallup,initslatest
pollonalcoholbeverages,announcedforthesecondstraightyearthat"Beer
AgainEdgesOutWineasAmericans'DrinkofChoice."
JuliaHerz,DirectorofCraftBeerMarketingfortheBrewersAssociation,
concluded,"Craftbeermarketshareissteadilyandconsistentlygrowing.A
grassrootsmovementisresponsibleforthissuccessasappreciatorscontinueto
tradeup."5
3
http://www.thefreelibrary.com/Craft+Beer+Segment+Continues+to+Set+the+Pace+for+the+Beer+Categ
ory...a0167648025
4
FranoisBiron.Agronomiste.MinistredelAgriculturedesPcheriesetdelAlimentationQubec.
GuestSpeaker.2010WinterHopsConference.UVMExtension.3/26/2010.
5
http://www.thefreelibrary.com/Craft+Beer+Segment+Continues+to+Set+the+Pace+for+the+Beer+Categ
ory...a0167648025
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Tofurtherexpressthispoint,whileoverallbeersalesweredown2.2%in2009,
craftbeersalesrose10.3%.6
3. Thenatureofthecraftbeerindustryisbuiltonproductdifferentiation,tradition,
innovation,quality,integrity,andcommunity.7Thesequalitiesalllend
themselvestosupportingalocalcommercialhopproductioneffort.Craft
brewersdesireforfreshnessandquality,theirsupportoflocaleconomies,their
interestinuniquenessasopposedtoubiquityallhelpinfluencetheirpurchasing
decisionmaking,andthustheyarenotsolelybuyingonprice.Thissupporthas
beenresearchedandquantifiedthroughthisfeasibilitystudy.
4. Thesizeandscaleofthemicroandcraftbreweries(theymustproducelessthan
2millionbarrelsperyear8)placetheminapositiontobeabletoworkwith
smallerscalelocalcommercialhopproduction.Theycanmoreeasilyadaptto
incorporatinglocalhopsintotheirproductionandrecipes,andtheirvolume
needs,oraportionoftheirvolumeneeds,areofasizeandscalethatwouldbe
feasibleforNewEnglandproducerstoattainandsupplyonaconsistentbasis.
Whathasbeendonetodate?
In1988,theVermontDepartmentofAgricultureinitiatedhopproductiontrialswith
CatamountBrewingCo.ofWindsor,Vermont.ThosetrialswereexpandedbyDr.
LeonardPerryattheUniversityofVermont.Reportsonthosetrialsareavailableat
http://www.uvm.edu/~pass/perry/hops.html.
InSeptember2008,asmallteamfromVermontandMassachusettstraveledto
Germany,theCzechRepublicandBelgiumtolearnmoreaboutequipmentusedthere
forharvestingandprocessinghops.Theteammetwithnumerousfarmerswho
produced,harvested,andprocessedhopsandwithmanufacturersofhopharvesting
andprocessingequipment.9
In2009theVermontAgencyofAgricultureFoodandMarketsandtheMassachusetts
DepartmentofAgriculturalResourcessecuredUSDASpecialtyCropBlockgrantsforthis
feasibilitystudytobeconductedandforUVMExtensiontodevelopandestablishan
organichopyardtrialing20hopvarietiesanddifferentcovercroppingtechniques.
http://www.brewersassociation.org/pages/businesstools/craftbrewingstatistics/facts
http://www.brewersassociation.org/pages/businesstools/craftbrewingstatistics/craftbrewerdefined
8
http://www.brewersassociation.org/pages/businesstools/craftbrewingstatistics/craftbrewerdefined
9
InformationprovidedbySteveJustis,VermontAgencyofAgriculture,FoodandMarkets,August2009.
7
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Methodology
Tocompletethefeasibilitystudy,thefirststepwastoresearchmarketdemandand
productspecificationsforthefinishedproduct.Craftbrewers,brewpubsand
homebrewsupplystoresinME,MA,NH,andVTwereidentifiedasthedirect
prospectivetargetmarketforaNewEnglandgrownhop.
Asurveyquestionnairewasdeveloped(seeappendices).Thequestionnairewas
availablebySurveyMonkey,asanemailattachment,andasatelephoneinterview.72
brewerswerecontactedandrequestedtoparticipate.Followupwasmadeby
telephoneandemail.47responseswerereceived,a65%responserate.
Theintentofthesurveywas:
todeterminewhatvarietiesofhopsthesebrewersuse
whatvolumeofthesehopstheyuse
whattheypay
howthesepricesfluctuate
whatpurchasingrelationshipstheyareengagedin
whattheparametersorlimitingfactorsoftheserelationshipsare
whattheywouldfindmostvaluableininfluencingtheirpurchasingdecisionfor
NewEnglandhops
whatthefinishedproductwouldneedtobeforthemtoconsiderusingaNew
Englandhop
whattheywouldconsiderafairpriceforaNewEnglandhop
Afterconductingthemarketresearch,thestudyturnedtohopproductionfeasibility.
CouldhopsgrowinNewEngland,whatarethebottleneckstocommercialproduction?
Bottlenecksresearchedincluded:
accesstoandcostofrawmaterialsforhopyardestablishment
accesstoandcostofmechanizedharvestingequipment
accesstoandcostofsecondaryprocessing
growingconditions
issuesaffectingcropyield
Followingresearchonthebottlenecks,productionmodelsfora1to10acrehopyard
wereexplored.Fourproductionmodelsweredevelopedthatcouldpresentafinancially
andlogisticallyfeasiblecommercialhopgrowingventure.
Theinformationwasthensummarizedintothisfinalreport.
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Initialfindings
BrewerswhorespondedtothisstudywereuniversallyinterestedinbuyingNewEngland
hops:94%,44outof47respondentsindicatedaninterestinpurchasingNewEngland
hops.Thisconclusionissupportedbyresearchconductedin2009byDuncanHilcheyof
NewLeafPublishingandConsulting,Ithaca,NY.10
Whilethebrewerswhorespondedtothisfeasibilitystudymaynotberepresentativeof
theentireNewEnglandbrewingcommunity,theirresponsesdidachievethemarket
researchgoalsofthestudywhichwereto
A. Determineifthereissufficientdemandtoabsorbaminimumof100,000
lbsofdried,NewEnglandaromahopsperyear,andatwhatpricepoint
B. Developahighlyqualifiedprospectlist
Thehighlyqualifiedprospectlistiscomposedofthosebrewerswhoaskedtoremain
involvedastheprojectasresearchanddevelopment,unfolds.Theyarehighlightedin
Boldunderthebrewersconsultedintheappendices.
Keypurchasingdecisionmakingfactors
Price
Brewersarehighlypricesensitive.Whiletheyareinterestedinbuyinglocal
hops,pricewillbeakeyfactor.Theprimarypricerangesconsideredas
acceptablepricepointsatwhichbrewerswouldpurchaselocalhopsiftheymet
theirotherrequirementswere:$5/lb,$810/lb,and$1015/lb.Atthe$510/lb
brewerswouldconsidersourcing100%oftheirhopsfromNewEngland
producersifthefinishedproductwasinterchangeablewiththeirexistingsupply
intermsofproductdeliverable.
ProductQuality
Makingbeerisbothascienceandanartform.Therearemanynuancesthatcan
affectthefinalproduct.Becauseofthis,theultimateachievementofabreweris
whentheycanconsistentlyproducethesamefinishedproductintaste,aroma,
appearance,andmouthfeel,brewafterbrew,frombrewhousetobrewhouse.
Becausehopscreateasignaturearomaandflavorprofileforabeer,hopsarea
keyingredientinanybeerrecipe.Becausethechemicalmakeupofhopsmay
changefromharvesttoharvestdependingongrowingconditionsand
geographicregion,themorethebrewerknowsaboutthemakeupofeach
10
Hilchey,D.TheMarketPotentialforNortheasternGrownHops.NewLeafPublishingandConsulting,
Inc.2009.
2010
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shipmentofhopshereceivesthemorehecanadjusthisrecipesothattheend
resultwillbeconsistentwithpriorbrews.
Tomeetproductqualityrequirements,NewEnglandhopswillneedtobe
submittedtoalabforchemicalanalysisandachemicalanalysiswillneedto
accompanyeachhopshipment.
ProductSpecifications
Whilethebrewercantcontrolthechemicalmakeupofahopfromharvestto
harvest,hehascometoexpecthishopstolookandperformacertainway.
Inordertomeetproductspecificationstobeconsideredaviablealternative,a
NewEnglandhopwouldneedtobepelletizedtoaT90standard,packagedin
Nitrogenflushed,vacuumsealed,foillaminatedpouches,andencasedin
cardboardboxes.Therearetwostandardofferings,four11lbpouchestoa44lb
box,orone44lbpouchtoa44lbbox.
11lbpouchesofvacuumsealed,nitrogen
flushedhoppellets.
Photocourtesyhttp://hopsextracts.com
T90Pellets.
Photocourtesyhttp://hopunion.com
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PurchasingDecisionInfluencersinbuyinglocal(NewEnglandgrown)hops
Stablepricepoint
Brewersarefrustratedandincreasinglyvulnerabletovolatilepricepointsand
productscarcityofhopsonthespotmarket.Thisisespeciallydisconcertingto
themasthecraftbeercategorycontinuestogrowandbrewersofallscaleand
sizecompeteforaccesstohopstomeettheirgrowingandexistingmarket
demand.
Personalrelationships
Brewers,similartobakersandchefs,taketheircraftseriouslyandpersonally.
Theyappreciatehavingconnectionstothoseprovidingtheiringredientsbecause
theyknowthatthequalityoftheingredientswillultimatelyimpactthequalityof
thefinishedproduct.Havinggrowersthattheycandevelopalonglasting,
personalrelationshipwithwillhelpsupersedepriceastheultimatepurchasing
decisionmakingfactor.
Environmentalawareness
NewEnglandscraftbrewersarewellawarethatthemajorityoftheinputsinto
theirproductscurrentlyoriginatefromtheMidWest,WestCoast,andEurope.
Anythingtheycandotohelpreducetheircarbonfootprintbybeingableto
purchaseinputsfromclosersourceswouldbeappreciated.
Localeconomicstimulation
NewEnglandcraftbrewersalsounderstandthenotionoflocaleconomy.Most
ofourcraftbrewersarelocalorregionalproducerswhoseproductsstayinNew
England,thereforekeepingtheirpurchasingdollarsinNewEnglandfurther
reinforcesthelikelihoodthattheirownproductswillbepurchased.
Marketing
Craftbrewersoftentightlywraptheirgeographiclocationsintotheircorporate
identity,leveragingasenseofplaceasadistinguishingattributeintheirsales
andmarketing.Bypurchasinglocalingredientstheycanfurtherstrengthenthis
marketingmessage.
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MarketResearchSurveyDetails
Ofthe72brewers,brewpubs,andhomebrewsupplystoressurveyed,34responded,
foratotalresponserateof47%.Fromtheresponsesgiven,totalbarrels(bls)brewed
(from26respondents)cameto370,970blsperyear,withanaverageof14,268blsper
brewery.Thesmallestbrewerclaimed210blsperyear,whilethelargestbrewercited
100,000blsperyear.
HopVarieties&Volume
ThemostprevalenthopusedbythebrewerswasCascade,followedbyHallertau,
Centennial,Golding,andWillamette,seechartbelow.
Totalvolumeofhopsusedannuallyby21breweriesreportingcameto126,482lbsof
driedhopsperyear,and2,600lbsofwethopsperyear.
NumberofBrewers
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ThetotalvolumeofCascadehopsusedby30reportingbreweriescameto81,860lbs
peryear.Volumesofthenextninemostprevalenthopswereasfollows:
Hallertau6,436lbs/yrfrom15respondents
Centennial5,400lbs/yrfrom16respondents
Golding5,250lbs/yrfrom12respondents
Willamette5,250lbs/yrfrom11respondents
Tettnang4,850lbs/yrfrom8respondents
Perle3,950lbs/yrfrom8respondents
Saaz3,550lbs/yrfrom9respondents
Magnum3,250lbs/yrfrom5respondents
Nugget:2,750lbslbs/yrfrom4respondents
NorthernBrewer2,650lbs/yrfrom9respondents
Columbus2,000lbs/yrfrom8respondents
Glacier1,850lbs/yrfrom3respondents
Inadditiontoseekingtounderstandthebrewerscurrenthopusageandvolume,the
studyaskedtheirpreferenceinwhatvarietiestheywouldbemoreinterestedinseeing
fromaNewEnglandsource,seechartonpage12.
Cascadetoppedthelistwith71%,22of31respondents,demonstratinganinterestina
NewEnglandCascade.Centennialwasthenextmostrequestedwith39%,12of31
respondents,askingforit.Thebrewerresponsespresentthemselvesfavorablyinterms
ofthelogisticalfeasibilityofbeingabletomeettheirvarietypreferencesbecause
CascadeandCentennialhappentobetwoofthevarietalsthatoutperformother
varietiesinNewEngland.11
11
InformationderivedfromcurrentNewEnglandhopgrowersincludingEugeneLEtoile,1997UVM
ExtensionHopsTrials,andUVMExtensionGrowerSurvey.
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WholeLeafvsPelletizedHops
83%,25of30respondents,saidtheyrequiredpelletizedhops.30%,9of30
respondents,saidtheyuseorcouldusedriedwholehops.23%,7of30respondents,
saidtheycouldusewetwholehops.Thetotalvolumeofwet,wholeleafhopsused
annuallybythese7respondentscameto2,600lbs.Thetotalvolumeofdriedwholeleaf
hopsusedannuallybythese8respondentscameto3,750lbs,andthetotalvolumeof
pelletizedhopsusedbythe24respondentscameto122,732lbs(seechartonpage13).
Atthesevolumes,wethopscouldsupportlessthanoneacreofcommercialproduction,
drywholehopscouldsupportupto4acres,andpelletizedhopscouldsupportupto120
acres.
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NumberofBrewersResponding
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AromavsBittering
ThefeasibilityofcommercialhopproductioninNewEnglandwillneedtofocuson
aromahops,ordualpurposehopsoverbitteringhopsfromNewEngland.Thisis
because:
1. Price:Bitteringhopsfunctionastheirnamesays,theyprovidebitternesstoa
beer,thebackboneuponwhicharomahopsthenlayercomplexity,flavorand
aroma.Becauseofthis,bitteringhopshaveevolvedintoahighlycommoditized
productwithanonelastic,pricepointaveraging$13/lb.Onlylargescale
operationsfocusedonefficienciesofscalecancompeteinthismarket.Aroma
hops,ontheotherhand,maintainproductdifferentiationcapabilitiesthatadd
valueandcancommandahigher,andmoreelastic,pricepoint.Aromahops
pricepointscanrangeashighas$25+/lb.
2. Contracts:Brewerstypicallylockinmultiyearcontractsforbitteringhops.While
theywillalsolockincontractsforcertainquantitiesofaromahopstheyknow
theyneed,theytendtoreservesomeoftheirbudgetforunexpectedpurchases,
enablingthemflexibilitytoexperimentandinnovate.Thisopensthedoorfor
themtopurchaseaNewEnglandhop.
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3. GrowingConditions:Bitteringhopsarehighalphaacidhopswhichareknownto
bedifficulttogrowinNewEngland.Havingahighalphaacidcontentisnota
prerequisitetoanaromahop.
4. CraftBrewerAudience:Craftbrewersaremorelikelytoexplorewithnewbeer
offerings,andseekoutnew,differentorunusualaromahopvarieties.Craft
brewersaremorelikelytoappreciatethevalueofterroir,uniquetraitsinahop
thatarederivedfromtheregioninwhichitwasgrown,inanaromahop.
5. ProductSpecifications:Becausearomahopscanbeaddedatdifferentstages
duringthebrewingprocess,thereareopportunitiesfornonpelletizedhopsso
evensmallscalecommercialgrowersinterestedinsellingwholedriedorwet
hopscouldparticipate.
6. CertainaromahopvarietiesareparticularlywellsuitedtogrowinginNew
Englandandarealsoinhighdemandfromthecraftbrewingcommunity.These
includeCascade,Centennial,Willamette,Chinook,andNugget.
PricePoints
Intermsofpricingtheissueiscomplex.Thehistoricalaveragepricefordriedhopsfrom
19912006was$1.80/lb,seechartbelow.However,in2007,failedEuropeancrops,
decliningacreageworldwide,aYakimawarehousefireandotherfactorsconspiredto
sendspotpricessoaringfrom$2and$3apoundto$30ormore.12
(source:NASS)
12
Fayston,J.The2007hopsshortageisover,theglutof'09ishere...TheOregonian.10/28/2009.
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NumberofBrewers
Brewersreactedbyenteringintomultiyearcontractsattheheightofthecrisissimply
toensuretheywouldbeguaranteedasupplyofhops.Insomecasesthishastied
brewersinto35yearcontractsata$1530/lbpricepoint,notnecessarilyincluding
shipping,eventhoughtheshortageisnowoverandthespotmarketpricingisback
downto$5/lb.
Becauseoftheseverevolatilityincommoditypricingandproductshortagethatthe
brewingindustryexperienced,themajorityofbrewerssurveyedreportedthatthey
wouldelectlongtermcommitmentswithlocalgrowersovercommoditycontractsand
spotmarketpurchasing,andwouldbewillingtopayaconsistentpriceforthisto
happenevenifthepricewerehigherthanthespotmarketprice,aslongasbothparties
felttheywerebeingwellserved.
Followingisachartdemonstratingwhatbrewershavesuggestedtheywouldconsidera
fairpriceforNewEnglandhops.Notethatthecurrentspotmarketpriceisaveraging
$58/lb.
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NumberofBrewers
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Afewofthebrewersconsidered$5/lbafairpricepointandbelievedthatwasstill
favorableeventhoughitsequivalenttocurrentspotmarketpricingbecausehistorically
spotmarketpricinghasaveraged$1.80/lbandthespotmarketcouldeasilyslipbackto
thislevel.Themajorityfeltthat$810/lbforNewEnglandhopswouldbereasonable.
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NumberofBrewers
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Percentageofabrewerstotalhopneedstheywouldconsidersourcinglocally
Atthepricepointbrewersidentifiedasapricetheyfeltfairforlocalhops,thestudy
thenaskedhowmuchofthetotalpercentageoftheirhopneedstheywouldsource
locallyifitwereavailable.Themajorityofbrewerssaidtheywouldbeinterestedin
sourcing100%oftheirhopneedslocallyifthequalitymatchedtheirexpectationsand
thepricepointfellwithin$510/lb.Abovethispricepointbrewerswouldstillconsider
buyinglocalhopsbutonlyasapercentageoftheirtotalhopneeds.
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ProductionFeasibility
Thefirstquestiontoaskregardingproductionfeasibilityis,canaNewEnglandgrower
growwhatthebrewerswant?Asnotedearlierintheresearch,theanswertothisis:
yes.Cascadeisthemostrequestedhop,andisavarietythatgrowswellinNew
England.InadditiontoCascadethereareseveralothervarietiesthatcouldgrowwell
hereandwouldbeofinteresttothebrewingcommunity.Brewershavealsoexpressed
aninterestinexperimentingwithanynew,uniquecultivarstheregioncancomeup
with.Havingahopuniquetoourregioncouldstrengthentheelementofterroir,
piquingglobalindustryinterest,andprovidingareasontojustifyapremiumpricepoint.
GrowingConditions
AccordingtotheHopsAtlas13optimalconditionsforgrowinghopsareasfollows:
alatitudebetween3555degrees
averagetemperaturefromAprilthroughSeptemberbetween1019C
averageprecipitationfromAprilthroughSeptemberof64569mm
averagedaylightduringthesemonthsbetween1019hrs/day
Thesefindingswerederivedbytakingtheclimatedatafortophopgrowingregionsin
theworld:George,SouthAfrica;TasmaniaandVictoriaAustralia;RioNegroArgentina;
OregonandYakima,US;Hallertau,Germany;Saaz,Czech;andWyeEngland.
Inaddition,theatlasidentifiedwelldrainingsandyloamasthebestsoilforgrowing
hops.
Giventheseparameters,itlookslikeNewEnglandhaseverycapabilitytocompetefor
commercialhopgrowing.Fromaverybasicfeasibilitycapacity,therightgrowing
conditionsdoexist:
theaveragelatitudeisinthe40's
theaveragetemperaturefromAprilthroughSeptember15.5C(60F)
theaverageprecipitationfromAprilthroughSeptemberis525550mm
theaveragehoursofdaylightfromAprilthroughSeptemberis13.5hrs/day
theFarmlandClassificationsSystemforVTSoilshighlightsFranklin,Addison
andRutlandcountiesascountieswithsandyloamsoils.Massachusettssoils
inFranklinandWorcesterCountiesarealsoknowntobewelldrained,sandy
loamsoils.
13
Barth, Joh Heinrich, Klinke, Christiane, Schmidt, Claus. The Hop Atlas. Joh Barth & Sohn, Nuremberg,
Germany. 1994.
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Page19
AkeycaveatforgrowinghopsinNewEngland,however,willbetheissueofbedrock.
Toerectthehopyardtrellis,thepolesneedtobeseatedatleast34intheground,
whichmeansoneneeds34oftopsoilbeforehittingbedrock.InmuchofNewEngland
thebedrocklieslessthan3belowthesurface.Whileitispossibletoadaptand
improveapoorgrowingmedium,itisnotsoeasyorcosteffectivetoblastthrough
bedrock.Socarewillneedtobegiventoevaluatingthebedrocksituationforeach
prospectivesitepriortoanydecisionbeingmadeondesiretoestablishahopyard.
Nowthatparametersrequiredforgrowinghopshavebeenestablished,whatwillitcost
tobuildahopyardandgrowhops,andisitcosteffective?
Infrastructure
AscommercialhopgrowingmovedWestintheearly20thcentury,infrastructurefor
valueaddedprocessingofhopsintheNortheastdied.Inordertodeveloparesurgence
ofacommerciallyviablehopcrop,tools,techniques,equipment,andserviceswillbe
requiredtohelpgrowersestablishtheirhopyardscosteffectively,andprovidethem
withtheabilitytotransformtheirrawhopsintothefinishedproductbrewersneed.
Atpresent,therearefewhopyardsuppliersgrowerscanturntoforsmallscale
commercialoperations.Growersareoftenforcedtopayretailpricesforsuppliessuch
asrhizomes,cables,andthesimplethoughtofbeingabletosourceuptoonehundred
2224polescanbedaunting.Whileaccessibilityisalreadyaweakness,itcanbe
exacerbatedbytheissueofquality.Thesourcingofqualityrhizomesinparticularcan
beverydifficult,evenwhenbuyingfromsupposedlytrustedsources.Bothlocal
growersandUVMExtensionhavereceivedhopsthatwerediseased,infestedor
otherwiseoflessthanidealquality.14
Inadditiontothedifficultiesinvolvedinlocatingmaterialsandsupplies,thecostof
establishingahopyardcanvarydramaticallybasedonthedesignbeingused.Different
designswillrequiremoreorlesspoles,moreorlessrhizomes,andsoon.Toprovidean
exampleofthis,pleaserefertotheappendicesforacomparisonofthesupplies
requiredandcosttoestablishasamplingofdifferenthopyarddesigns.
InfrastructureSolution
GorstValleyHops,wasestablishedin2005inWisconsintoalleviatebarrierstoentryfor
smallscalehopgrowers.Thebusinesshasfocusedonidentifyingandsolvingthe
bottlenecks,anddevelopingbestpracticesforsmallscalehopgrowerstoemployso
thattheycanbecommerciallysuccessful.GorstValleyHopshasbecomeareputable
sourcesmallmidwestgrowersinterestedincommerciallygrowinghopscanturnto.
14
PhoneconversationswithGeneLEtoile,FourStarFarm,andRosalieMadden,UVMExtension,August,
2010.
2010
Page20
ThecommercialmodelGorstValleyhasdevelopedworkssuchthatallthreepartiesthe
brewer,theprocessor,andthegrowerbenefit.15TheGorstValleymodelisbasedona
valuesharechartergrowerprogram,inwhichthegrowersagreetosendtheirannual
hopsharvesttoGorstValley.Inreturn,GorstValleyprovidesthemwiththeir
researchedandtestedhighdensityhopyarddesign,technicalassistancetoimplement
it,ongoingtechnicalsupportduringthegrowingseasonforthefirstfouryears,direct
sourcingandwholesalepricingofallthesourcematerialsrequiredtoestablishtheir
hopyard,accesstoequipmentinnovationsandresearchanddevelopment,anda
marketingoutletthatstrivesforafairandprofitablepricefor100%oftheirharvest.In
thismodelGorstValleysharestheproceedsofthehopsales6040with60%goingback
tothegrowers.
Theabilityforgrowerstohaveaccesstoareplicable,provendesignforoptimalyield
andproductivityforasmallscalecommercialhopyard,completewithaccessto
commerciallyavailablesourcematerialsatwholesalepricing,withqualityassured
rhizomesisthefirstrequirementtocreatingacommerciallyviablehopcrop.Tothis
end,AtlanticHops,anewventurebeinglaunchedbyMichaelRoffman,inpartnership
withGorstValleyHopswillbeopeningintheNortheastin2011.AtlanticHopsintends
toestablishaNortheastvaluesharegrowerprogramandactasadistributorofGorst
ValleyproductsandservicestoNewEnglandcommercialhopgrowers.16
SecondaryProcessing
Evenwithbarrierstoentryremovedfromthegrowingoperation,issuespersist.Access
tosecondaryprocessingisthenexthurdle.BrewersarelookingforaT90pellet
product,packagedinvacuumsealed,nitrogenflushedfoillaminatedpouches.
WhatisaT90Pellet,howisitmade,andhowisitpackaged?
T90Pellets(are)amilledandpelletizedpreparationfromwholeleafhopsT90hop
pelletsarepreparedfromleafhopswhichhavebeenhammermilledintoapowderand
thepowdersubsequentlypelletizedbypassingthroughaconventionalpelletdie.They
containallthevegetativeandlupulinmaterialofrawleafhopsandcanbeusedasafull
replacementforleafhopsinthebrewingprocess.Baledhopsarebrokenupandpassed
intoanairstreamwhichdeliversthemtoahammermill.Heavyforeignmaterialsdrop
outandmetalfragmentsareremovedusingmagnets.Theconehopsaremilleduntil
theypassthroughasievewhichiscommonlyofa912mmmesh.Thepowderfrom
manybalesismixedandhomogenizedinablenderandthenconveyedtoapelletdie,
mostcommonly4or6mmindiameter.Thepelletsareimmediatelycooled,normallyto
atemperatureofbetween17C.Cooledpelletspassoverashakerwheredustis
removedandrecirculatedthroughtheplant.The"clean"pelletsarepackagedin
15
16
PhoneconversationwithJamesAltwies,founder,GorstValleyHops,September7,2010.
PhoneconversationwithMichaelRoffman,founder,AtlanticHops,August,2010.
2010
Page21
laminated,plastic/aluminumfoilpouches,evacuatedandboxed.Thepacksmaybe
backflushedwithcarbondioxideornitrogengastoproduceasoftpackcontainer.17
Whileitispossibletoconductthissecondaryprocessingonfarm,manyfarmsmaynot
beinterestedindoingmorethangrowingthecrop,andmanyarefindingitdifficultto
sourceandobtainsatisfactoryresultswiththeirsecondaryprocessingequipment.18
AtlanticHopswillprovidecommercialprocessingofNewEnglandhopsthatwillensure
secondaryprocessingisnolongerabarriertoentry,andthatNewEnglandcanproduce
aconsistent,professionalgradefinishedproduct.AtlanticHopswillofferitsvalueshare
growerprogramforgrowerswhoaresimplyinterestedingrowingthecrop,itwillalso
offersitservicesforhiretogrowerswhowouldliketogrowandselltheirownhopsbut
wouldliketopayforthesecondaryprocessingservices.
CriticalMass
EvenifeachfarmproducesitsownT90pelletizedproductthathasbeenchemically
analyzed,andpackagedinanitrogenflushed,vacuumsealedfoillaminatedpouch,the
factremainsthatmostgrowerswillbelookingatanaveragesizeofaoneacrehopyard,
atleastinitially.Aoneacrehopyardisexpectedtoyieldanaverageof1,500dried
poundsoffinishedproduct.Thisyieldwilllimittheprospectivetargetmarketbecause
largercraftbrewerswillrequiremoreproductthanasinglefarmercanproduce.Given
theproductofasinglevarietalwilldifferfromfarmtofarm,abrewercannoteasily
combinethem,evenifheadaptshisrecipe.AccordingtoMichaelGerhart,headbrewer
atOtterCreekBrewing,Wetrytobuyallourhopsatonetimeandfromthesamecrop
soweknowtheinformationperhopswillbestandardforthewholecropwearebuying
andtherecipewewillbemakingforthatyear.19
BycombininghopsfrommultipleNewEnglandfarmstogether,AtlanticHopswillbe
abletodevelopcriticalvolumeofeachvarietalitofferssothatcraftbrewersofallsize
andscalecanpurchasefromahomogeneousproduct.Incombiningmultiplefarms
hopstogether,idiosyncrasiesfromeachgrowerarealsominimized,thuscreatinga
productthatismoreconsistentlyinlinewiththestandardprofileforthathopvariety.
Byhavingcriticalmass,andaregionalproductthatbrandstheregionfirstandforemost,
AtlanticHopscanattractawarenessfortheregionsefforts,whichintheendwill
facilitatethemarketingeffortsofindividualproducers.
17
http://www.hopunion.com/hoppowderpellets.html
ConferenceCallwithRogerRainville,BorderviewFarmandAgResearchFacility,9/17/2010.
19
ConferenceCallwithMichaelGerhart,HeadBrewer,OtterCreekBrewingCompany,7/6/2010.
18
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Cashflow
Thefinalrequirementiscashflow.Oncetheinfrastructureisinplace,canthehopyards
operateinamannerthatisfinanciallyfeasible?
Toassistitsgrowersinbecomingfinanciallyviable,GorstValleyHops,hasresearched
growingandharvestingtechniquestooptimizeyield,andisdevelopingequipmentfor
smallscaleacreagethatoptimizesefficiency.Inthesummerof2010,forexample,Gorst
ValleyHopsconductedharvestingstudiestodeterminethemostadvantageous
techniquesforhandharvestingonacommercialscale.Theyalsobegantestinga
mechanicalpickertheydesigned.
AccordingtoestimatesprovidedbylocalNewEnglandgrowers,UVMExtension,anda
commercialgrowerinWashington,manualharvestingonaverageyields1lbofdried
hopsperhour,20seetablebelow.
Manualharvestingestimatesgiven
RickPedersen,PedersenFarms,NY
1lbdriedhops(1bine)perhour(1lb/hr)
JasonPerrault,PerraultFarms,Inc,WA 100people,30days,13acres(1.08lbs/hr)
GeneLEtoile,FourStarFarm,MA
1lbdriedhops(1bine)perhour(1lb/hr)
LeonardPerry,UVMExtension,VT
24manhourstopick5lbsofdriedhops,
(0.21lbs/hour)
Atarateof1lbofdriedhopsperhour,itwillbeneartoimpossibletogeneratea
positivecashflowforacommercialhopventure.
IntheGorstValleyHopstrials,however,theydeterminedthatifthegrowercutthe
entirebinebutonlyharvestedthetoponethirdofthebine,where94%ofthehop
conesresided,thegrowerwouldreducepickingtimeby42%,to35minutesperdried
lb.Bygoingastepfurtherandstrippingthebine,andsortingtheconesonamesh
screen,thegrowercouldreducepickingtimeto20minutesperdriedlb.Usinga
mechanizedpickerandmechanizedsorter,thegrowercanreducethetimeto3
minutesperdriedlb,a95%efficiencygain.21
IfagrowerweretoemployGorstValleyHopsharvestingtechniques,andutilizea
mechanicalharvesterandsorter,thehopfeasibilityequationcanbetransformedinto
afinanciallyrewardingoutlookforcommercialhopgrowinginNewEngland.Please
refertotheattachedcashflowsfordetails.
20
InformationprovidedbyRickPedersen,PedersonFarm,NY,3/26/2010,JasonPerrault,PerraultFarms,
WA,3/26/2010,GeneLEtoile,FourStarFarms,MA,8/20/2010,and
21
EmailcommunicationfromJamesAltwies,founder,GorstValleyHops,9/14/2010.
2010
Page23
Notethatinallfourscenariosofsalesanddistribution(participatinginthevalueshare
program;sellingwholedriedhops;usingAtlanticHopsprocessingservices;ordoing
onfarmpelletizing),onlythecashflowmodelsthatemploystrippingandsortingand
mechanizedharvestingofferapositivereturnoninvestment,andonlythe
mechanizedharvestingcashflowmodelsofferthepossibilityofasubstantialannual
netincome.
Todevelopthecashflows,thestudyassumedthefollowing:
Income
pricepointsfordriedwholehops:$10/lb
pricepointforpelletizedhops:$15/lb
incometogrowerfromvalueshareprogram:$9/lb(60%of$15/lb)
Expense
operatingexpensesnotincludinglaborandprocessing:$2,500/acreperyear22
InfrastructureExpense
Growersinvolvedinthevalueshareprogramcanexpecttopayapproximately$10,000
toestablishaoneacrehopyard.Growersnotinthevalueshareprogramcanexpectto
payapproximately$12,000toestablishaoneacrehopyard,seeappendicesforsample
hopyardinfrastructurebudgets.
Yield
Ayieldof1,500driedpoundsperacrewasusedastheaverageexpectedyield.This
numberwasderivedfromhistoricaverageyieldsfromGorstValleyHopsgrowersfrom
averageyieldingvarieties.
22
ConservativeestimatedderivedfromhistoricactualdatafromGorstValleyHopsgrowers
2010
Page24
OtherIssuesAffectingGrowingCapabilityandCommercialProduction
Accordingtoexperiencedgrower,RickPedersen,PedersenFarms,NY,whilehopsmay
beahighmaintenancecrop,thisistrueofanyfieldcrop.InRicksexperience,hops
aresimilartofieldcorn.Ifyouknowhowtogrowfieldcornsuccessfully,youshouldbe
abletodowellwithhops.23Followingarecertainspecificelementsoftheoperation
thatcanaffectthesuccessofcommercialhopgrowers.
Disease&Pests
Hopshavebeennotoriousasacropthatgrowswellinthewildbutwhosecommercial
cultivarstendtobeproblematic.Hopsareeasilysusceptibletodownymildew,
powderymildew,aphids,andspidermites.Arigorouspestanddiseasemanagement
regimewillbearequiredelementofanycommercialgrowingoperation.
Nutrients
Nutrientsandsoilamendmentscanbothboostaplantsproductivityandalleviate
diseaseandpestpressure.HopspreferapHof6.06.2,oramildlyacidicsoil.
Growersshouldtesttheirfieldsannuallyandamendtheirsoilstoprovidetheideal
growingmediumfortheirplants.Notethatamendingsoilsbasedontheirspecific
needsiscriticalbecauseoverapplicationofNitrogenbasedfertilizerwillcausesappy
growththatisparticularlysusceptibletodiseaseandpests.24
Inadditiontoamendingthesoilforfertility,therearealsoamendmentsbeing
designedtoassistwithdiseaseandpestcontrol.AnewproductfromGermanyfor
example,BiplantolMykosV,isanorganicamendmentthatisabsorbedbythecapillary
rootsystemandfortifiesaplantsresistancetobacteriaandfungalinfestation
includingpowderyanddownymildew.Theresultisahealthyandvitalplant,which
canmorereadilywithstandpestanddiseasepressure.25UVMExtensionistrialing
othersoilamendmentsandgroundcoverstobeabletoprovidefurther
recommendationsforNewEnglandhopgrowers.
Irrigation
Hops,similartoCucurbitaceaeenjoy,andrequire,watering,butoverheadwatering
willencourageandspreaddisease.Thereforeinstallationanduseofdripirrigationis
recommendedforcommercialgrowers.Thebinesalsoneedgoodairflowandspacing
betweenthemtoencourageadry,diseasefreeenvironment.Hoprootspreferawell
23
HoppingtoIt!Conference,RickPedersenPresentation,March26,2010.
Kneen,Rebecca.SmallScaleOrganicHopProduction.LeftFieldsBC.2004.
25
https://www.biplantol.com/produkte.php?content=3
24
2010
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drainedsoil.Ifagrowerhasheavysoil,installingadrainagesystemwillbean
importantfactortohelpensureasuccessfulhopyard.
TimingofEventsintheGrowingSeason
Hopsrequirespecifictimelyattentiontoplantpruning,irrigation,andharvesting.
Hopsmustbepickedwhenfullyripe.Earlyharvestingcanhinderlupulindevelopment
andloweralphaacidcontentbyupto20%.Lateharvestingcanlowerthembyas
muchas10%.26Inessencethisistypicalofanyfieldcrop.Experiencedgrowerslearn
tounderstandthenuancesofeachcroptheygrow,andwithalittleexperienceand
effort,especiallybeingabletobenefitfromtheknowledgeofothersmallscalehop
growingexpertswhohaveundergonerecenttrialanderrorsuchasthegrowersfrom
GorstValley,bringingourNewEnglandgrowersuptospeedispossible.
Yield
Yieldcanvarygreatlybyvariety,byweatherconditions,andbyindividualfarm
growingpractices,philosophies,andgoals.Asanexample,aplantsindividualyield
canvarybyasmuchas40%dependingonwhattimetheirrigationwasrunpriorto
harvest.Becauseofthis,James,atGorstValleyHops,hasfounditbeneficialforfarms
todevelopproductiongoalsandproductionmetricsbasedonindividualplant
productivityinsteadofoverallyieldperacre.Whenfarmsfocusonhelpingeach
plantreachitsfullpotential,theyseeanincreaseinoverallyieldbecausethey
identifiedwitheachplantgrowthstage,workingtomaximizethepotentialateach
step,whichinturnequatestomoreconsistentyield.Whengrowersmeasurecrop
inputsandproductionbasedonpoundsperacretheytendtooverlookthenuancesof
productivity.Atoursizeandscale,afocusonefficiencyoverproductivitynegatively
impactsfinancialreturn.27
AtGorstValleyHops,anaverageproducinghopvarietycanproducealowyieldof
1,000lbsofdriedhops;anaverageyieldof1,500lbsofdriedhops,andastrongyield
of2,000lbsofdriedhops.UsingtheGorstValleyHopshopyarddesignand
participatingintheAtlanticHopsvaluesharegrowerprogramitislikelyNewEngland
growerscanachievesimilarresults.28ExistingNortherngrowerRickPedersen,
PedersenFarm,NYaverages8001,200lbsofdriedhopsperacre(4,0006,000wet
hops),howeverheacknowledgedthathisgrowingsystemisnotfullyoptimizedand
hehasnotbeenabletoprovideindividualizedplantattention.29GeneLEtoile
26
Virant,Majda,Majer,Dusica.HopStorageIndexIndicationofaBrewingQuality.InstituteofHop
ResearchandBrewingZalec.January2006.
27
EmailcommunicationwithJamesAltwies,founder,GorstValleyHops,9/27/2010.
28
ConferenceCallwithJamesAltwies,founder,GorstValleyHops,9/7/2010.
29
2010
Page26
30
harvested100lbsofdriedhopsfrom70plants. Ifthisisextrapolatedtothe1,283
plantsperacrethatGorstValleyHopsrecommends,thiswouldextrapolatetoayield
of1,832driedpoundsperacre,whichisinlinewithGorstValleyHopsyield
projections.
Inestimatingwettodryyields,expectashrinkageratioof1:5,thereforeeverywetlb
harvestedwillyield1/5thofapoundofdriedhops.31
TimetoMaturity
Whenwillhopplantsreachfullmaturity?
Ittakesapproximatelyfouryearsforahopbinetoreachfullmaturity.Inthefirstyear
expectnoharvest,inthesecondyearexpect40%ofafullharvest,inthethirdyear
expect90%,andinthe4thyearplanonfullproduction.32
1styear
=
0%harvest
=
40%harvest
2ndyear
rd
3 year
=
90%harvest
th
4 year
=
100%harvest
LowTrellisSystems/CurbAppeal
Anotheranglethisresearchwastoinvestigatewastheinterestorneedforgrowing
lowtrellishopsandthefeasibilityofdoingso.
Traditionallygrownhopsaretrainedupstrandsoftwineriggedacrossan18foothigh
trellissystemandthenhandtiedatthetoptoaseriesofoverheadcrosswires.Come
harvest,thehopbearingvinesarecutandhauledtopickingandcleaningstations.
Withlowtrellissystems,plantstrainthemselvesupandacrossplasticmesh,or
netting,ona10foothightrellissystem.Hopsareharvestedinthefieldbyhandor
usingamobilelowtrellishoppicker.Thevinesareleftonthemeshwheretheydie
offoverthewinterandregrowthenextspring.
Thepotentialbenefitsofalowtrellissysteminclude:
1. Bettercurbappealespeciallyforfarmslocatedinmoreurbanenvironments
suchasMassachusetts.Alowtrellissystemwouldbelessvisiblefroma
distanceand,beingshorterinheight,anysprayingactivitieswoulddrawless
attention.
30
ConferenceCallwithGeneLEtoile,FourStarFarm,7/13/2010.
32
EmailcorrespondencefromJamesAltwies,founder,GorstValleyHops,9/23/2010.
31
2010
Page27
2. Loweroperatingexpenses.Lowertrelliseseliminatetheneedforstringing,in
whichtwineistiedtothetrelliswires,andtraining,inwhichthestrongest
shootsofeachhopplantaretrainedupthestring.Theycanalsobeeasierto
harvest.Thesechangescouldreduceannuallaborexpensebyupto30%per
year.33Annualsuppliesexpensecanalsobediminishedbecausethemesh
netsremainintactfromyeartoyearwitha10yearlifespan,unlikecoirtwine
whichneedstobereplacedeachyearatanaveragecostof$125/acre.34Low
trellisproductionsystemsalsoenablegrowerstoapplypesticideswith
directedorcoveredsprayersthatlowertheamountofpesticidesrequired,and
theyuselessfertilizer,furtherreducingoperatingcosts.35
3. Environmentalbenefits.Giventhepesticidescanbeappliedinamore
targetedanddirecteffort,aloweramountofpesticidesisrequired,thus
lesseningtheamountofpesticideaddedtotheenvironmentandtheriskfor
pesticidedrift.36Conversely,however,thistheoryisquestionedbyEdward
Pagewhonotesthathigherchemicaluseisrequiredfortillingandpruning.37
4. Lowerstartupexpenses/easiertoestablish.Itiseasierandlessexpensiveto
sourceandinstall1012polesandnylonmeshthantopurchaseandinstall20
24polesandsteelcabling.AccordingtoEdwardPage,whodidacost
comparisonbetweenhightrellisandlowtrellis,itcostsabouthalfasmuchto
setupalowtrellishopyard,$6,000/acre.38
Despitetheseexcellentbenefitsthereareseveralissuesaffectingthecommercial
feasibilityofgrowinglowtrellishopsinNewEnglandatthistime.
1. Commerciallowtrellisharvestingequipmentiscostprohibitive,ranging
between$200,000$400,000perharvester.
2. Increasedincidenceofdisease.AccordingtoJulienVenne,ProjectManagerat
QubecsCentredeRechercheetdeDveloppementTechnologiqueAgricole
deLOutaouais,thereisstrongconcernthatintheNortheastsrainy,humid,
anddiseaseproneclimate,havingbinesoverwinterwouldencouragedisease
ifthesporesoffungaldiseasesoverwinteronhopcrownsandligneous
tissues.Thiscouldkeephighlevelsofdiseaseinoculumsinthefieldand
exacerbatethediseasecontrolprocess.39InthePacificNorthWesttheyare
33
USDAARS.LowerHopTrellisesforHigherProfits.CropManagement.21January2008.
Ward,L.YakimaHeraldRepublic.Someplasticmeshcouldsavestatehopfarms.Newtechniquehas
potentialforthebeermakingcrop.May30,2005.
35
36
http://www.ars.usda.gov/is/AR/archive/jan08/hops0108.htm
37
Page,E.B.HopTrellising&Budgets.7/26/2008.
38
39
EmailCommunicationJulienVenne,ProjectManageratQubecsCentredeRechercheetde
DveloppementTechnologiqueAgricoledeLOutaouais,5/25/2010.
34
2010
Page28
experimentingwithusingdiseaseresistantvarietiesandbeatingthebinesoff
themeshoncetheyhavefrozenoverinwintertocounterthisissue.
3. Limitedvarieties.Notallhopsaresuitedtolowtrellismanagementandmany
ofthelowtrellisvarietiesthatdoexistarenotinhighdemandbythe
brewers.40
4. Patents.Manylowtrellissystemandhopvarietiesarepatented.Thismay
presentmoredifficultiesandexpenseinsourcingvarietiesandhopyard
supplies.
5. LowerYields.AccordingtoresearchconductedbyJasonPerrault,Godin&
Page,andJohnHenning,hopsgrownonalowtrellissystemwillhavealower
yieldthanhightrellisedhops.Yieldscouldrangeanywherefrom2050%less.
4142
Becauseofthis,geneticistJohnHenningisresearchingwhatgeneorgenes
areresponsibleforshortergrowthtoaidinselectionofhopsvarietiesthatmay
respondmorefavorablytolowtrellissystems.43
Theconclusionregardinglowtrellissystemsisthatwhileitwouldbeinterestingto
investigate,theclearpathtowardsanimmediatecommerciallyviablehopcropwould
betocontinuedownthetraditionalhightrellishopspath.Theadventofmore
commerciallyavailablemobileharvestingmachinerycoupledwithmoreresearchinto
lowtrellishopvarietiesandthevalidationorrefutationwithrespecttodiseaseissues
giventheoverwinteringofhopcrownsandligneoustissuesinNewEnglandwinterswill
helpfurtherthediscussiononthelongtermpotentialofalowtrellissystem.Inthe
appendicesisanexpiredpatentforamobile,lowtrellisharvester.
OnFarm/DoItYourselfTechniques
GivengrowersinNewEnglandhavehadtorelyontheirowningenuity,trialanderror,
andpersonalexpensetogrow,harvest,andprocesshopsinrecentdecades,severaldo
ityourself,lowcostsolutionshavebeendevelopedtosolveproductionbottlenecks.
DoItYourselfHopPickers
Atpresenttherearenocommerciallyavailablehoppickersfor110acrehopyards.
SomefarmshavetriedimportingoldermachinesfromEasternEurope,butaccessto
partsandreliabilityareanissue.Because110acrecommercialhopyardswere
commonintheearlytwentiethcentury,Germanyalonehad80,000100,000hopyards
thatwereoneacreorless,andNewYorkandOregonoperationsofthetimewere
40
EmailcommunicationwithRosalieMadden,UVMExtension,5/25/2010.
Page,E.B.,Godin,R.HopyardConstruction:BudgetingandEconomics.CSUAgExp.Station.
42
EmailcommunicationwithRosalieMadden,UVMExtension,5/25/2010.
43
http://www.ars.usda.gov/is/AR/archive/jan08/hops0108.htm.
41
2010
Page29
44
comparableinsize,yield,andproductiontothesefarms, severalpatentsformachines
doexistforthesescaleoperations.Thisstudyresearchedandrecirculatedthese
patentsinhopesnewdesignsormachinistswouldbeinterestedinbuildingprototype
machinesthatcouldbetested,andifeffective,replicatedandsoldtoday.Copiesof
thesepatentsareattachedasappendicestothisreport.Threedesignsdidemergefrom
thiseffort,twobylocalfabricatorHugoGervais,andathirdbyJefferyCox.These
designswouldrangeinpricefrom$3,900to$27,000,thelowercostmodelshandling
approximately1/3ofanacreandthemoreexpensivemodelsbeingabletohandle
multipleacres.GorstValleyHopsisalsodesigningandtestingasmallscalepickerthat
willbeabletomanageuptoanacreperhopvariety,thereforeatotalofthreeacresif
followingthethreevarietyhopplanting.Theyplantohavethehoppickerandahop
sortercombinationavailableforsalethroughAtlanticHopsby2012for$15,000orless.
Alloftheseoptionsarewellunderthe$250,000expenseofapickerdesignedforthe
largefieldsoutWest,andallabletoprovideareasonabletimeframeforreturnon
investment,of5yearsorless.
Note:Whenevaluatinghoppickersitisessentialtosearchforadesignthatwill
minimizeshatterordamagetothehop.Theaveragerateofdamageexperienced
duringhandharvestinghoversaround2%.Ideallyonewouldwantamechanizedpicker
toequalorimproveonthatrate.TheGorstValleyHopspickeriscurrentlyexperiencing
ashatterrateofbelow2%.45
DoItYourselfOasts
Oastscanbebuilteconomicallyfrommaterialsaroundthefarm.Afivegallonpailwith
a3diametercomputerfanandameshscreencandryuptoahalfpoundofdriedhops
atatime(~2hoursworthofhandpicking).A30gallonbarrelgarbagecanwitha6fan
wouldfurtherincreasethevolumeofdryingcapacity;anda16x24x8rectanglebuilt
outofwoodorothermaterials,withan18to2fanandanylonmeshsecuredmidway
downcoulddryuptoofanacreatatime.46
Inadditiontoselfmadeoptions,AtlanticHopswillofferGorstValleyHopsoastdesigns
andoastkitsforNewEnglandhopgrowers.ThecostofaGorstValleyHopsOastwillbe
highlydependentonthefansizeneededastheirdesignusesaninverseblowing
technique,ratherthanblowingairintothehops,itissuckingairthroughthehops.An
oastforaoneacrehopyardoastwillrunapproximately$5,000,anoastfor25acreswill
runapproximately$10,000andanoastfor5+acreswillrunapproximately$17,500.
44
Barth,JohHeinrich,Klinke,Christiane,Schmidt,Claus.TheHopAtlas.JohBarth&Sohn,Nuremberg,
Germany.1994.
45
PhoneConversationwithJamesAltwies,founder,GorstValleyHops,9/7/2010.
46
PhoneConversationwithNewEnglandhopgrowerJonathanBlumberg,August8,2010.
2010
Page30
Exteriorviewofahomemadeoast.Suppliesaresimple2x4stocreatetheframe,
1x2stoaffixthescreen,a4x8screen,tyvektoformthewalls,andacircularfan.
PictureofGeneLEtoilesFourStarFarms,MA.Photocreditr.wilson
Insideofahomemadeoast,notethemeshscreeninstalledpartwayuptoallow
airtocirculatebelowandabovethehops.Notetheseriesofoastsinthe
background,enablingmorevolumetobedryingsimultaneously.Pictureof
GeneLEtoilesFourStarFarms,MA.Photocreditr.wilson
2010
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DoItYourselfSorting
Sortingmechanismsenableagrowertogofromhandpickinghopsonebyoneoffthe
binetostrippingthemintoapileonasortingtableandquicklyextricatingthehopsfrom
thechaff.Sortingisanareaoftheharvestingprocessthatcangreatlyincreasea
growersefficiency.JamesAltwies,founderofGorstValleyHops,notesthattobe
commerciallyviable,growerscantoverlyconcernthemselveswithremoving100%of
thestemsandleaves.AccordingtoAltwies,thenationalindustrystandardsallowforup
to2.5%ofstemandleafsubstancetoremainattachedtoahopandstillbecalledhops.
Soonecanleaveuptoaninchofstemattachedtoahopandhaveitstillapprovedasa
hop.Ahomemadesortingsystemcanbeachievedthroughcreatingaseriesofsorting
tablesoutofmeshedscreensaffixedtoarectangularframe.A1screenwouldbeused
firsttosortoutbigleaves,allowingthehopstofallontoasecond.25meshscreenthat
canthenbeusedtosortoutfinaldebrisandallowasortertoremoveanyexcess
detritusfromahopbeforeusheringtheconesintoboxesthatcanthenbesenttodry.
Foroptimalefficiency,mechanizingonessortingsystemisadvised.GorstValleyHops
offersamechanized,angled,oscillatingsortingsystemthathascapacityforoneacreper
hopvariety.TheGorstValleyHopssortercombinedwiththeGorstValleyHopshop
pickerisexpectedtobeavailablefromAtlanticHopsin2012atatotalpricepointof
$15,000orless.47
DoItYourselfCompacting
Ideallyhopsshouldbecompacteddownto10lbspercubicfootandbailed.Thiswill
makethemeasiertotransportandhelpretaintheirstoragequality.48Oncecompacted
andbailedthehopscanremaininrefrigeratedstorageuntilsoldorpelletized.At
presenttherearenoknowncommerciallyavailablecompressorsspecificallydesigned
forsmallscalehopgrowers.Existinggrowershavesuggestedusingatrashcompactor,
orpressingdownonabagofhopsusingascrewaugerplate,asrelativelyeffective
meanstocompresstheirhops.49
GorstValleyHopsiscurrentlyinvestigatingtheneedforcompressingmechanismsfor
smallscalehopgrowers.
47
ConferencecallwithJamesAltwies,Founder,GorstValleyHops,9/7/2010.
49
48
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DoItYourselfPelletizing
Asdemonstratedinthemarketresearch,anoverwhelmingnumberofbrewerspreferor
canonlyusepelletizedhops.Alowcostsolutiontocreatingonesownpelletsisto
grindhopsintoapowderusingakitchenmeatgrinder,50orideally,ahammermill,and
sendingthemintoasmallscalepelletmillequippedwithadie.Adiewillproduce
the6mm(T90)pelletthatbrewersareaccustomedto.
Smallsizedhammermillscanbepurchasedfor$1,700orless,andsmallscalepellet
millscanbefoundforunder$2,400,seePelletProsunderadditionalpersonsconsulted
formoreinformation.5152
SmallScalePelletProsHammermill. 130lb/hrcapacity
50
ConferencecallwithRogerRainville,UVMExtensionhopresearchfarm,9/17/2010.
http://www.pleasanthillgrain.com/hammer_mill_pulverizer.aspx;
http://www.meadowsmills.com/forsalehm.htm
52
http://www.pelletpros.com/id68.html
51
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SmallScalePelletProsPelletMill.80lb/hrcapacity
Note:Thekeyconcerntorememberwhenpelletizingisthatheatcreatedduringthe
processcandamagethehops.Takecaretoprocessslowlyandstopasoftenasneeded
toallowthemachinestocooldown.Thehopsandhoppelletsshouldnotreacha
temperaturehigherthan112F.Tokeepaneyeonthetemperatureyoucanusean
infraredthermometer,whichcanbefoundatmosthardwarestores,forapproximately
$20.Youcanalsoalleviatehowquicklythepelletsheatupbypouringfewerhopsinata
time.AccordingtoRogerRainville,ifyoukeepthefeedslowyoucankeepthe
temperaturedownandprocessanaverageof10poundseveryfewminutes.53
DoItYourselfChemicalLabAnalysis
Severallaboratoriesofferchemicalanalysisservices,aninexhaustivelistisprovidedin
theappendices.Ataminimum,growerswillneedtohaveananalysisforalphaandbeta
acidscompletedontheirhops.Informationonmoistureandoilcontent,willalsobea
requirementfromsomebrewers.GorstValleyalsodoesaphysicalexamoftheirhops
usingtheguidelinesprovidedbytheAmericanSocietyofBrewingChemistsandthe
USDA.Acopyofthecompletedanalysisshouldaccompanyeachpackageofhopssold.
53
ConferencecallwithRogerRainville,UVMExtensionhopresearchfarm,9/17/2010.
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DoItYourselfVacuumSealPackaging
Whileitwillbedifficulttoachieveanitrogenflushonabudget,onecanataminimum
vacuumsealtheirpelletizedandwholedriedhopsathomewithsimpletoolssuchasthe
FoodSaver,homeusefoodgradevacuumsealsystems,thatcostunder$200,54orby
usingvacuumsealSpaceBagsthatarealargersolutionandcouldmeetthebrewers
requestsfor11lband44lbpackages.55
Note:Packagingandequipmentneedstobefoodsafe.
DoItYourselfNitrogen/CO2flushingandVacuumSealing
Foramoreprofessionalandcommercialoperationonecaninvestinafoodgrade
nitrogenflushing,vacuumsealingmachineforlessthan$30,000.Severalmodelsof
smallscalemachinesthatcombineflushingwithnitrogenandvacuumsealingare
availablefromIndia,suchasthetwoshownherebyFujiImpulseAmerica56and
Indvac57.Theprovidersofthemachinescanalsosupplythefoillaminatedpouches
requiredforpackaging.TheFujiImpulseVG602whichcanprovideuptoa600mm
lengthseal,rangesfrom$21,00024,000andasetof200foillaminatedpouchesthat
wouldfit11lb/pouchrun$330/order.ThecompleteproductspecificationsfortheFuji
ImpulseVG402/602seriesarelocatedintheappendices.
FujiImpulseVG402/602SeriesMicro
ComputerControlledNozzletypeVacuum
andGasFlushingImpulseSealer.
Indvacnozzletypeflushingandsealingmachine.
54
http://www.foodsaver.com/Category.aspx?id=c&cid=87
https://www.spacebag.com/10/PriceList.dtm
56
http://fujiimpulseamerica.thomasnet.com/viewitems/impulsesealersvacuumgasflushsealing/
controllednozzletypevacuumgasflushingsealer
57
http://www.indvacindia.com/nozzletypeflushingsealingmachines.htm
55
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DoItYourselfClimateControl
Hops need to be kept between 2632F. This can be achieved through any regular
household freezer, or growers can invest in walkin freezer/cooler storage units.
Growerscanalsoleasespacefromcommercialclimatecontrolledwarehousessuchas
VermontRefrigeratedStorage.58
Conclusions
ThisreporthasdeterminedthatisfeasibletogrowacommercialhopcropinNew
England.Thereissufficientdemand,thereissufficientpriceelasticity,andthereisnow
theinformation,technology,supplies,andequipmentavailabletomeettheneedsofa
110acrecommercialhopyard.
TherearefourwaysthatappearcommerciallyfeasibleforgrowinghopsinNew
England:
Scenario1:
ParticipatinginavaluesharegrowingprogramwithAtlanticHops
Scenario2:
Sellingwholehops,minimallyprocesseddirecttobrewers
Scenario3:
UsingAtlanticHopsforprocessingservicesandsellingpelletized
hopsdirecttobrewers
Scenario4:
Sellingdoityourselfpelletizedhopsdirecttobrewers
Inallinstances,thebestpotentialforreturnoninvestmentandnetincomeexistswhen
thegrowerutilizesmechanicalharvestingandsorting.
58
For contact info see Barney Hodges, Vermont Refrigerated Storage, under additional persons consulted.
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IncomePotentialandReturnOnInvestment
Scenario1
Scenario2
Scenario3
Scenario4
AverageYield
1,500driedlbs 1,500driedlbs 1,500driedlbs 1,500driedlbs
PerAcre
AverageNet
$4,640
$5,090
$5,090
$12,910
IncomePer
Acre
AverageReturn 5years
5years
6years
4years
OnInvestment
for1stAcre*
Levelof
IndividualRisk Low
Moderate
Moderate
High
Whilethepotentialtogeneratenetincomeperacreishighestinscenariofour,inwhich
thegrowercreatesthevalueaddedfinishedproductonsite,theultimate
recommendationistoadoptscenarioone,inwhichgrowersparticipateinavalueshare
growingprogramwithAtlanticHops.Thisisbecausescenarioonerepresentstheleast
riskwhilestillpresentingastrongpotentialforfinancialreturn.
1. BestSolution:ParticipateinAtlanticHopsvaluesharegrowingprogram
Benefits:
LeastInfrastructureExpense
UnlimitedaccesstoGorstValleyHopsTechnicalAssistanceandResources
ApplicabletoAllGrowers
Nosecondaryprocessingorsalesandmarketingrequiredofthegrower
LowestRisk
EncouragegrowerstoparticipateintheAtlanticHopsvaluesharegrower
program.TheAtlanticHopsValueShareGrowerprogramwillseektominimize
risktoitsgrowersateverystageinthegrowing,production,andsalesand
marketingprocessbyprovidingthemwithtechnical,logistical,andinfrastructure
support.Farmsinthevalueshareprogramwillbenefitfromwholesalepricing
onhopyardsupplies,complimentarytechnicalassistance,triedandtested
hopyarddesignsandproductiontechniquestheseeffortsasdesignedtoassist
inoptimizingproductionefficiencyandyield.ThenAtlanticHopswilluseits
expertiseandequipmenttoprocessahighqualityfinishedproductthatmeets
theproductspecificationandvolumeneedsofthebrewingcommunity,and
marketandselltheproductatapricethatreturnsafairprofittoitsgrowers.
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Hopyard:
Recommendstartingwithoneacreandexpandinguptotenacres.Usea3
varietyplanting,with1/3ofhopyardpervarietytostaggerharvesttimesand
minimizethreattoentirecropfromweather,pestordiseaseissuesthatmay
affectaparticularvariety.
Economicfeasibility:
$10,000
Anticipatedhopyardinfrastructureexpenseperacre:
Anticipatedharvestinginfrastructureexpense:
Oast(Year2):
$5,000for1stacre
$10,000for25acres
$17,500for5+acres
MechanicalPicker(Year3)
$5,000forupto3acres
MechanicalSorter(Year3)
$5,000forupto3acres
TotalInfrastructureExpenseforFirstAcre: $25,000
TotalOperatingExpensePerAcre:
$8,860
TotalGrossIncomeat100%Production: $13,500
(assumingreceiving$9/lbforwholedriedhopsfromAtlanticHops)
NetIncomePerAcre:
$4,640
ReturnonInvestmentforFirstAcre:
5years
2. GoodSolution:Sellwholehops,minimallyprocesseddirecttobrewers
Concerns:
LimitedaccesstoGorstValleyHopsknowledgeandresources
Marketdemandcanonlysustainafewgrowers
Growerswillneedoutgoingsalespersonality
Growerswillneedtomaketimeforsalesandmarketing
Lackofsufficientclimatecontrolledstoragespacecouldbeanissue.
Moderaterisk
Encouragegrowerstoinvestinmechanicalharvestingandsorting,useahigh
hoptrellissystem,sendhopstoalabforchemicalanalysisandselldried,whole
hopsdirectlytobrewers.Thissolutiondoespresentasolidpotentialforprofit
andreturnoninvestmentwithminimalsecondaryprocessingrequired.The
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issueswillbepotentialissueswithqualityofthefinishedproduct;limited
demandforawholehopproduct;limitedstoragespaceunlesstheproductis
compacted,orsignificantclimatecontrolledwarehousespacecanbeleased;and
relianceonthegrowersabilitytosecuresalesofhisproduct.
Hopyard:
$12,000
Oast(Year2):
$5,000for1stacre
$10,000for25acres
$17,500for5+acres
$5,000forupto3acres
$5,000forupto3acres
$9,910
(assumingsellingwholedriedhopsat$10/lb)
NetIncomePerAcre:
$5,090
5years
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3. GoodSolution:UseAtlanticHopsprocessingservices,sellpelletizedhopsdirect
tobrewers
Concerns:
Individualfarmvolumecouldbealimitationonmarketdemand
Growerswillneedtomaketimeforsalesandmarketing
Moderaterisk
Encouragegrowerstoadoptmechanicalharvestingandsorting,utilizeahigh
trellishopssystem,andcontractprocessingandpackagingoftheirhopsfrom
AtlanticHops.Retrievethefinishedproductandsellindividualfarmhops
directlytobrewers.Inthissolutiongrowerscantakeadvantageofprocessing
servicestoproducethefinishedproductbrewersarelooking.Thisenablesthe
growertofocushisattentiononhiscorecompetencygrowingtherawproduct,
andengagingothersfortheircorecompetencies.Thishelpsensureeveryones
timeisbestused,andthatrisktoqualityofthefinishedproductisminimized.
Hopyard:
$12,000
Oast(Year2):
$5,000for1stacre
$10,000for25acres
$17,500for5+acres
$5,000forupto3acres
$5,000forupto3acres
Anticipatedprocessinginfrastructureexpense:
2Chestfreezers(Year2):
$2,000
$17,410
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(assumingsellingpelletizedhopsat$15/lb)
NetIncomePerAcre:
$5,090
6years
4. RiskySolution:Sellingdoityourselfpelletizedhopsdirecttobrewers
Concerns:
Issueswithprocessingcouldimpactsuccess
Volumeandproductqualitycouldbealimitationonmarketdemand
Growerswillneedtomaketimeforprocessing,salesandmarketing
Highrisk
Encouragegrowerstoadoptmechanicalharvestingandsorting,utilizeahigh
trellishopssystem,purchaseahammermill,pelletmillandvacuum,nitrogen
flushsealingmachine.Thissolutionrepresentsthegreatestpotentialfor
incomeandreturnoninvestment,andalsothegreatestrisktothegrower.The
growerwillbeonhisownforallaspectsofgrowing,harvesting,producing,and
sellingafinishedproductthatmeetstheproductspecificationsofthebrewing
community,atavolumeandpricepointthatgeneratesapositivereturn.Ifthe
growercanmaintainanaverageyieldof1,500lbsofdriedfinishedproduct,
achievethequalitystandardsofthebrewingindustry,anddevelopthesalesand
marketingskillstomarkettheproduct,thegrowercanstandtogenerateupto
$12,910innetincomeperacre.
Hopyard:
$12,000
Oast(Year2):
$5,000for1stacre
$10,000for25acres
$17,500for5+acres
$5,000forupto3acres
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$5,000forupto3acres
Anticipatedprocessinginfrastructureexpense:
2Chestfreezers(Year2):
$2,000
VacuumNitrogenFlushSealer(Year2):
$24,000
PelletMill(Year2):
$2,400
HammerMill(Year2):
$1,700
$9,590
(assumingsellingpelletizedhopsat$15/lb)
NetIncomePerAcre:
$12,910
4years
2010
Page42
NextSteps
Itisevidentthereisstrongdemandforlocalhops,andgoodpotentialfortheabilityto
growhopsprofitablyinNewEngland.Theinfrastructure,whichwasoriginallyakey
barriertomarket,isnowbeingdevelopedtosupportsmallscalecommercialgrowersin
NewEngland.
Ifproducersgothroughtheeffortofinvestingtimeandcapitalintostartinga
commercialhopventure,butlackthesupporttheyneedtodeveloptheirbusinessplan
andgainaccesstonecessarytechnicalexpertise,theeffortmaywellbelost.
FollowingisarecommendationforhowVermontAgencyofAgriculture,Foodand
MarketsandtheMassachusettsDepartmentofAgriculturalResourcescouldensurethat
suchanendeavorisgivenitsbestopportunityforsuccess:
1. AssistAtlanticHopsinestablishingitsoperation.
NewEnglandneedstheprocessingcapabilitiestoproduceaprofessionalproduct
thatwillmeetmarketexpectations.Italsoneedsaccesstotheequipment,and
technicalexpertiseGorstValleyHopshasalreadydevelopedandtestedforits
smallscaleMidWestfarmers.Havingaprocessingfacilitythatiswillingto
processtheproductandpartnerwiththefarmswithamissionofprovidinga
goodproductatafairvaluetobrewersandreturningafair,profitableincometo
theproducersisawinwin.
2. Outreachtoexistinggrowers/farmers
Theagencieswillneedtoreachouttoexistinggrowers.Someofthemany
reasonshopsarecitedasdifficulttogrowarebecausetheyarebeinggrownby
peoplewhodontgrowcropsforaliving.Mostofthebasicissueswithhopsare
thesamebasicissuesyouwillfindwithanyothercrop(theyneedwelldrained
soil,theyneedfertilizer,theyneedpestcontrol,theyneeddedicatedtimingthe
harvestiseverything).Producerswhogrowacresofcorn,vegetables,and
grainsalreadyknowandunderstandthefundamentalelementsofwhatittakes
togrowacropsuccessfully.Existingandexperiencedgrowersandfarmersneed
tobethetargetaudienceifgrowinghopsistodedevelopedasacommercial
enterprise.
3. BusinessPlanning&CoordinationwiththestateFarmViabilityPrograms.
Witheachfarm,giventhisisanewventureandunexploredterritoryforthem,
andalsoanewcropfortheregion,havingthemgothroughthebusiness
planningprocessforimplementingthenewcropandevaluatingitsimpacton
thefarmbusinessandfamilyqualityoflifewillbeessential.Thiswillhelpensure
thateachfarmcanmapoutonpaperhowtheywouldgoaboutimplementing
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Page43
thenewcrop,understandwhatitwouldtakeontheirparticularfarm,whatit
wouldcost,andwhatthepotentialreturnwouldbe.Theymustbeableto
understandandevaluatehowitmightimpactotherareasofthefarmand
whetherthenetreturnwouldbebetterthancontinuingwiththeircurrent
productionornot.Itisimportantthatthisstepbedonewhilestillinplanning
mode,soadecisiononwhetherimplementingtheplanisintheirbestinterestor
notismadebeforeanyadditionalresources,time,andefforthavebeen
allocated.
4. ImplementationandBusinessPlanningTechnicalAssistance
Provideongoingsupportforthefarmsfor4yearsafterinitialimplementationto
helpassistwithanalyzing,planning,anddecisionmakingforthenewventure
andtheoverallfarmoperation.Thisincludesbusinessplanreview,analysisand
updating,andtechnicalexpertisespecifictoareasofconcernproduction,
processing,salesandmarketing,etc.Thisthirdparty,objectivesupportwillhelp
ensureconcernsareaddressedproactivelythusprovidingalargerdegreeof
likelihoodofsuccessforeachfarm,andtheirlongtermcommitmenttothe
project.
ActionItems
1. Identify10growersinMA&VTwhowouldbeinterestedinparticipatingin
AtlanticHopsValueShareGrowerProgram
2. Vetfarmsites
a. Conductasitevisittoevaluatethelogisticalfeasibilityofeachfarm.Ata
minimumthesitewillneed3oftopsoilbeforereachingbedrock.
AtlanticHopswillalsoassesseachfarmssiteforadditionalattributes
suchassoilstructure,waterholdingcapacity,andseasonalwindloads.
3. Workwiththegrowerstoexplaintheopportunity,andenrolltheminthe
program.Thiswillrequireacommitmentofestablishingaoneacrehopyardat
anexpenseof$10,000andthepurchaseofapicker,sorter,andoast,foran
additionalexpenseof$15,000overyearstwoandthree.
4. Potentiallyfindingfundingtooffsetcostofcapitalinfrastructureexpenseforthe
firsttengrowers,orfordairyfarmerswishingtoparticipate.
5. BeginFarmViabilitybusinessplanningandAtlanticHopsValueShareGrowing
Programtechnicalassistancewitheachfarm.
6. AtlanticHopswillprovideoversightandguidancewithTechnicalAssistance
duringestablishmentofthehopyard,andgrowingandharvestforfirstfour
years.
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7. Maintaincommunicationloopwiththebrewingcommunity.Letthebrewersin
thehighlyqualifiedprospectlist(seebrewersinBoldintheappendices)know
oftheplan,engagethemintheR&Dphase,andleveragetheirinputand
feedbacktodevelopafinishedproductthatwillmeettheirapprovalandbe
readyforsalebyyear3.
8. ProvideongoingFarmViabilitybusinessplanningandtechnicalassistance
services
a. Provideanannualbusinessplanreview,analysisandplanforthe
upcomingyear.Forfirstfouryears
b. ProvideongoingannualTechnicalAssistanceinspecificareasofexpertise
asneededforeachfarm.Forfirstfouryears
Budget
10farms
Year1
PerFarm
#Farms
Total
HopyardInfrastructure
$10,000
10
$100,000
BusinessPlan
$4000
10
$40,000
TechnicalAssistance
inAreasofExpertise

$3000
10
$30,000
TotalBudgetYear1 $170,000
Years24
PerFarm/Year#Farms
Years Total
$15,000
10
$2000
10
3$60,000
$2000
10
Harvest/DryingInfrastructure
AnnualBusinessPlanReview
andAnalysis
AnnualTechnicalAssistance
InAreasofExpertise
TotalBudgetNextThreeYears
2010
$150,000
$60,000
$270,000($90,000/year)
AppendixASourcesofInformation
Barth,H.J.,Klinke,C.,Schmidt,C.TheHopAtlas.1994.Nuremberg,Germany.Joh,
Barth&Sohn.
Fayston,J.The2007hopsshortageisover,theglutof'09ishere...TheOregonian.
10/28/2009.
Hilchey,D.TheMarketPotentialforNortheasternGrownHops.NewLeafPublishing
andConsulting,Inc.2009.
Kneen,Rebecca.SmallScaleOrganicHopProduction.LeftFieldsBC.2004.
Neve,R.A.Hops.Champman&Hall.1991.
Page,E.B.,Godin,Ron.HopyardConstruction:BudgetingandEconomics.CSUAgExp.
Station.
Tomlan,M.TingedWithGoldHopCultureInTheunitedStates.UniversityofGeorgia
Press.Georgia.1992
Virant,Majda,Majer,Dusica.HopStorageIndexIndicationofaBrewingQuality.
InstituteofHopResearchandBrewingZalec.January2006.
Ward,L.YakimaHeraldRepublic.Someplasticmeshcouldsavestatehopfarms.New
techniquehaspotentialforthebeermakingcrop.May30,2005.
InternetResources
http://www.brewersassociation.org/
http://www.thefreelibrary.com/Craft+Beer+Segment+Continues+to+Set+the+Pace+for+
the+Beer+Category...a0167648025
http://hopsextracts.com
http://hopunion.com
http://fujiimpulseamerica.thomasnet.com/viewitems/impulsesealersvacuumgas
flushsealing/controllednozzletypevacuumgasflushingsealer
http://www.indvacindia.com/nozzletypeflushingsealingmachines.htm
https://www.biplantol.com/produkte.php?content=3
http://www.ars.usda.gov/is/AR/archive/jan08/hops0108.htm
http://www.pleasanthillgrain.com/hammer_mill_pulverizer.aspx;
http://www.meadowsmills.com/forsalehm.htm
http://www.pelletpros.com/id68.html
http://www.foodsaver.com/Category.aspx?id=c&cid=87
https://www.spacebag.com/10/PriceList.dtm
http://blog.foothillhops.com/2009/01/01/foothill_hops_20091114521flv.aspx
http://www.centralvt.com/climate/climate.htm
http://www.lindemanarchives.com/LA%20History.html
http://www.rssweather.com/climate/Vermont/Burlington/
http://maps.google.com/maps/ms?hl=en&ie=UTF8&msa=0&msid=11400620226975507
9477.00048524ed0b04bf595d6&ll=42.366662,
71.235352&spn=2.840979,5.767822&z=7&source=embed
http://www.massbrewersguild.org/craftbeer/index.php/memberbreweries/
http://groups.google.com/group/vermonthops/topics
http://www.indiehops.com/
http://www.freshops.com/
http://www.gorstvalleyhops.com/
http://www.examiner.com/hopsinmadison/hopsgrowingbusiness2007shortage
revisited
http://www.examiner.com/beerinnational/toptenhopvarietiesusedbyamerican
craftbrewers
http://vermontbrewers.com/
http://www.lewbryson.com/nyprogress.htm
http://www.freepatentsonline.com/
http://www.czhops.cz/tc/bibliography/bibliography10.html
http://www.youtube.com/user/cohopsfarmer#p/a
http://www.northeasthopalliance.org/
http://www.wolfheiztechnik.de/en/pkp/unternehmen/historie.html
http://meeting.asbcnet.org/default.cfm
Commercial Feasibility of Local Hops

2010
AppendixBListofPersonsConsulted
GrowersandHopExperts
DwayneWheeler
Claremont,NH
(603)5423870
Eugene(Gene)LEtoile
FourStarFarms
496PineMeadowRoad
Northfield,MA
(413)4982968
[email protected]
FrancoisBiron
Conseilleramnagement,innovationetagroenvironnement
Ministredel'Agriculture,desPcheriesetdel'Alimentation
CentredeservicesagricolesdeGatineau
999rueDollard
Gatineau,Qubec,CANADAJ8L3E6
(819)9868544x236
[email protected]
HeatherDarby
UniversityofVermontExtension
AgronomistandNutrientManagementSpecialist
278S.MainSt
St.Albans,VT05478
(802)5246501x206
[email protected]
JamesAltwies
GorstValleyHops
6082283117
[email protected]
JasonPerrault
PerraultFarms,Inc.
11051LateralA
Toppenish,WA98948
(509)8482497

2010
JonathanBlumberg
83SouthStanleyHillRd
Vassalboro,ME04989
(207)9233123
JulienVenne
Centrederechercheetdedveloppementtechnologiqueagricoledel'Outaouais
(CRDTAO)
188,rueJeanneD'Arc,suite200
Papineauville,Qubec,CANADAJ0V1R0
(819)4275511x461
[email protected]
Larry&KateFisher
FoothillHops
[email protected]
(315)4952451
MichaelRoffman
AtlanticHops
POBox1055
Larchmont,NY10538
(914)8345130
[email protected]
PeterHingston
JeffreyCox
CherryHillFarm
409HighlandRoad
Springfield,VT05156
(802)8855088
[email protected]
[email protected]
PuterbaughFarms
HopsDirect,LLC
686GreenValleyRoad
Mabton,WA98935
(888)9723616
http://www.hopsdirect.com/

2010
RickPedersen
PedersenFarms
1798CountyRoad4
SenecaCastle,NY
(315)7810482
[email protected]
RogerRainville
BorderviewFarms&AgResearchFacility
146LineRd.
Alburgh,VT05440
(802)7963292
[email protected]
RosalieMadden
CropsandSoilsTechnician
UVMExtension
278S.MainSt.,Suite2
St.Albans,VT05478
(802)5246501x445
SteveParks
AmericanBrewersGuild
Abgbrew.com
[email protected]
Anthony(Tony)Palmiero
TractorLogging
345EastChurchSt.
EastHardwick,VT05836
(802)4726503
[email protected]

2010

Brewers/BrewPubs/HomebrewSuppliers
MAINE
AllagashBrewing
JasonPerkins,headbrewer
100IndustrialWay
Portland,ME04103
(800)3305385
[email protected]
AndrewsBrewingCompany
AndyandBen,brewers/owners
4975HighSt.
Lincolnville,ME04849
(207)7633305
[email protected]
AtlanticBrewingCompany
Doug,brewer
15KnoxRoad
BarHarbor,ME04609
(207)2889513
[email protected]
BarHarborBrewingCo
8MountDesertStreet
BarHarbor,ME04609
(207)2884592
BelfastBayBrewingCompany
100SearsportAve.
Belfast,ME04915
(207)3384216
www.belfastbaybrewing.com
BlackBearMicroBrewery
TimGallon,owner/brewer
19MillStreet,Suite4
Orono,ME04473
2079492880
[email protected]

2010

Bray'sBrewpub&Eatery
Rob,brewmaster
678RooseveltTrail
Naples,ME040550548
(207)6936806
CascoBay=Shipyard,seeShipyard
FederalJacksBrewpub&Restaurant
8WesternAvenue
Kennebunk,ME04043
(207)967.4322
Gearys
SteveSpear,headbrewer
38EvergreenDrive
Portland,ME04103
(207)8782337
GrittyMcDuffs
AndrewHeyner&Jake,brewers
396ForeStreet
Portland,ME04101
(207)772BREW
InnonPeaksIsland
33IslandAve
PeaksIsland,ME04108
(207)7665100
KennebecRiverBrewery
Jim,headbrewer
ForksResortCenter
TheForks,ME04985
8007657238
LiberalCupPublicHouse&Brewery
115WaterSt.
Hallowell,ME04347
(207)MADBREW

2010

MaineCoastBrewingCompany
102EdenStreet
BarHarbor,ME04609
(207)2884914
PeakOrganicBrewingCo.
JonCadoux,owner/brewer
110MarginalWay#802
Portland,ME04101
(207)5865586
[email protected]
OakPondBrewery
101OakPondRd
Skowhegan,ME04976
(207)4743233
SeaDogBrewingCo.
26FrontStreet
Bangor,ME04401
(207)9478009
SebagoBrewingCompany
Tom,brewer
48SanfordDrive
Gorham,ME04038
(207)8562537
ShipyardBrewingCo
AlanPuglsey,owner
DavidHall,headbrewer
86NewburySt.
Portland,ME04101
(207)7610807
[email protected]
[email protected]
SundayRiverBrewery
StuMason,brewer
1SundayRiverRoad
Bethel,ME04217
(207)8244ALE

2010
Note:callonMondays
MASSACHUSETSS
BostonBeerWorks
TimMorse,CorporateBrewer
61BrooklineAve
Boston,MA02215
(617)8962300
BerkshireBrewingCompanyInc.
GaryA.Bogoff,owner
12RailroadStreet
SouthDeerfield,MA01373
Tel(413)6656600
[email protected]
BlueHillsBrewery
Todd,sales
1020TurnpikeStreet#3B
Canton,MA02021
(781)8212337
[email protected]
TheBostonBeerCompany
JenniferGranville
OneDesignCenter,Suite850
Boston,MA02210
(617)3685000
BrewBank
CambridgeBrewing
WillMeyers,brewmaster
1KendallSquare,Bldg100
Cambridge,MA02139
6174941994
[email protected]
CambridgeCommonsBrewery
Ginger,owner
Cambridge,MA
(978)5516477

2010

CapeAnnBrewing
JeremyGoldberg,brewer
27CommercialStreet
Gloucester,MA01930
(978)2814782
[email protected]
CapeCodBeer
Beth&ToddMarcus,owners/brewers
1336Phinney'sLane
HyannisMA02601
(508)7904200
[email protected];[email protected]
CiscoBrewers
Jay,brewer
P.O.Box2928
NantucketMA02584
(508)325.5929
[email protected]
BYOB(Cody)BrewingCompany
SeanCodyBrewer/Owner
36MainSt.
Amesbury,MA01913
(978)3783424
[email protected]
GardnerAleHouse
DaveRichardson
7ParkerSt.
Gardner,MA01440
(978)6690122
[email protected]
HarpoonBrewery
AlMarzi,V.P.Operations
SeanCornelius,assistantV.P.Operations
306NorthernAve.
Boston,MA02210
(888)HARPOON
[email protected];[email protected]

2010

HaverhillBrewery
JohnCurtis,brewer
100WashingtonStreet
Haverhill,MA018325500
(978)3732337
tapbrewpub.com
MayflowerBrewingCompany
Drew,brewer
12ResnikRd
Plymouth,MA02360
(508)7462674
[email protected]
MercuryBrewingCompany
Dan,brewer
23HaywardSt.
Ipswich,MA01938
(978)3563329
[email protected]
NorthamptonBreweryBarGrille(JohnHarvard'sBrewHouse)
MariaPoulinas,brewer
11BrewsterCourt
Northampton,MA010603801
(508)8752337
[email protected]
OpaOpaSteakhouse&Brewery
Themis,owner
169CollegeHighway
Southampton,MA010739320
(413)5270808
opaopasteakhousebrewery.com
PittsfieldBrewWorks
34DepotStreet
Pittsfield,MA012015130
(413)9973506
pittsfieldbrewworks.com

2010
RockBottomRestaurant&Brewery
ScottBrunelle,brewmaster
115StuartStreet
Boston,MA02116
(617)7422739
rockbottom.com
Note:Besttimetocallis910am.
WachusettBrewingCompany
DaveHoward,Howieheadbrewer
175StateRoadEast
Westminster,MA01473
(978)8749965x30
[email protected]
WatchCityBrewingCompany
JocelynandFrank,owners
AaronMateychuck,brewer
256MoodyStreet
Waltham,MA02453
(781)6474000
watchcitybrew.com
NEWHAMPSHIRE
GraniteCask
6King'sSquareUnitA
Whitefield,NH03598
(603)8372224
[email protected]
MountWashingtonHomeBrewSupply
ADivisionofMerrill'sAgway
678MeadowStreet
Littleton,NH03561
6034448803
[email protected]
PortsmouthBrewery
Tod,brewer
56MarketStreet
Portsmouth,NH03801
6034311115
[email protected]

2010

SmuttynoseBrewingCo
David,ExecutiveBrewer
225HeritageAve
Portsmouth,NH03801
(603)4364026
SevenBarrelBrewery
PlainfieldRoad
ColonialPlaza,Rt12A
WestLebanon,NH03784
(603)2985566
TuckermanBrewingCompany,LLC
KirstenNeves
ManagingMember
POBox1058
64HobbsStreet
Conway,NH03818
(603)4475400
[email protected]
WhiteBirchBrewing
Bill,brewer/owner
1368HooksettRd,Unit6
Hooksett,NH03106
(603)2448593
VERMONT
TheAlchemist
23SouthMainStreet
Waterbury,VT05676
(802)2444120
BobcatCafe&Brewery
MarkMagiera,brewer
5MainStreet
Bristol,VT
(802)4533311

2010
BreweryattheTrappFamilyLodge
AlanVanAnda,brewer
700TrappHillRoad
POBox1428
Stowe,VT05672
8022538511
HillFarmsteadBrewery
ShaunHill,owner/brewer
403AHillRoad
GreensboroBend,VT05842
(802)5337450
JasperMurdock'sAlehouse/NorwichInn
PatrickDakin,brewer
325MainStreet
P.O.Box908
Norwich,VT05055
(802)6491143
Lawson'sFinestLiquids
SeanLawson,owner/brewer
Warren,VT05674
(802)2728436
[email protected]
LongTrail
MattQuinlin,brewmaster
5520USRoute4
BridgewaterCorners,VT050359600
(802)6725011x207
[email protected]
MadisonBrewing
428MainStreet
Bennington,VT05201
(802)4427397
MagicHatBrewingCompany
ToddHaire,brewer
5BartlettBayRoad
SouthBurlingtonVT05403
8028626114x2012

2010
McNeillsPub&Brewery
RayMcNeill,owner/brewer
90ElliotStreet
Brattleboro,VT05403
(802)2542553;[email protected]
NorthshireBrewery
108CountyStreet
Bennington,VT05201
(802)6810201
OtterCreekBrewing
MikeGerhart,brewmaster
793ExchangeStreet
Middlebury,VT05753
(802)3880727
[email protected]
RockArt
ReneeandMattNadeau,owners/brewers
234WilkensStreet
Morrisville,VT05661
(802)8889400
SouthRoyaltonMarket
ScottRussell,homebrewmanager
105ChelseaSt
SouthRoyalton,VT05068
(802)7632400
SwitchbackBrewingCo.
BillCherry,owner/brewer
160FlynnAvenue
Burlington,VT05401
(802)6514114
[email protected]
ThePerfectPear
AdamColter,owner/brewer
48SouthMainStreet
Bradford,VT05033
(802)2225912
[email protected]

2010

TheShedBrewery
JimConroy,brewer
1859MountainRoad
Stowe,VT05672
(802)2534364
ThreeNeedsBrewery
207CollegeStreet
Burlington,VT05401
(802)6580889
TroutRiverBrewery
Dan&LauraGates,owner/brewers
Route5;P.O.Box165
Lyndonville,VT05851
(802)6269396
VermontHomebrewSupply
147E.AllenStreet
Winooski,VT05404
(802)6552070
[email protected]
TheVermontPub&Brewery
144CollegeStreet
Burlington,VT05401
(802)8650500
ZeroGravityCraftBrewery
Destiny,brewer
15St.PaulStreet
Burlington,VT05401
(802)8612999

2010

AdditionalPersonsConsulted
AllenMatthews
CenterforSustainableAgriculture
106HighPointCenterRoom312
UniversityofVermont
Colchester,VT05446
(802)3181041
AtulKantVerma
ManagingPartner
ElegantEngineers,AnISO9001:2008CertifiedCompany
C82,Sector10,Noida201301(U.P.)
INDIA
Tel:911202525503/2444892
Mobile:919810146982
Email:[email protected]
[email protected]
Websitehttp://www.elegantengineers.com
http://www.pouchpacking.com
BarneyHodgesIII
VermontRefrigeratedStorage
1287NorthBinghamSt.
Cornwall,Vermont
[email protected]
www.sunriseorchardsvt.com
(802)9890255
DauenhauerManufacturing,Inc.
111125FifthStreet/POBox1744
SantaRosa,CA95402
(707)5460577
www.dmfg.com
EnidWonacott
ExecutiveDirector
NOFAVT
POBox697
Richmond,VT05401
(802)4343821
[email protected]

2010

HugoGervais
CustomFabrication
[email protected]
IndiaBurnettFarmer
ProgramDirector
RutlandAreaFarmandFoodLink
P.O.Box561
EastPoultney,VT05741
(802)4177331
[email protected]
JunSota
FujiImpulseAmerica
[email protected]
(847)2369190
www.fujiimpulseamerica.com
MacyMullican
ShelburneVineyard
TheVermontFoodProject,refrigeratedwarehouse
(802)7343431
Pellet Pros, Inc.
4004 W. Kimberly Rd.
Suite C
Davenport, IA 52806
(563) 386-4300
[email protected]
SteveJustis
VermontAgencyofAgricultureFood,andMarkets
116StateSt.
Montpelier,VT05620
(802)8283829

2010
AppendixCBrewerQuestionnaireTemplate
Whatisthenameofyourbrewery?
Howmanybarrelsdoyoubrewperyear?
Whatarethetopfivehopsyouuse?
1.
2.
3.
4.
5.
Howmuchofeachdoyouuseperyear?(inlbs)
1.
2.
3.
4.
5.
Howmuchtotalaromahopsdoyouuseperyear?(inlbs)
Howmuchtotalbitteringhopsdoyouuseperyear?(inlbs)
Whichvarietiesofhops(ifnotlistedinthefiveabove)wouldyouliketoseeavailable
morelocally?
Howdoyouprefertousehops(whole,pelletized)?Pleasedescribe
Whataretheproductspecificationsandqualityrequirementswewouldneedtobeable
tomeetforyoutoconsiderbuyingfromalocalsource?Pleasedescribe(iepackaging,
labanalysis,pelletizedvswhole,etc,etc)
Howdoyourhopscomepackagedandshipped?

2010

Areyouundercontractforyourhops?
Ifsowould/couldyouconsiderbuyinglocalhopsandwhendoesyourcontractcomeup
forrenewal?Couldyoubuylocalhopsevenifyouareundercontractandifsoupto
howmuchofyourtotalvolumeofhopusage?
Whatisyourcurrentsourceforhops?Pleaselistsuppliersandstate/country.
Whatareyoucurrentlypayingforyourhops?
Doesthisincludeshipping?
Ifnot,whatdoyoupayforshipping?
Howmuchofyourtotalhopvolumewouldyoubewillingtobuylocallyifitmetyour
qualityrequirementsandproductspecifications?
Wouldyoupreferastablepriceforlocalhopsthatmayormaynotreflectthemarket
ratebutisastablepricethatyouandthegrowercanbothdependon?Orwouldyou
preferthehopscompeteatmarketrate?
Ifyouwouldprefertobeabletorelyonaknownpriceforaknownproduct,whatwould
youseeasafairratethatyouwouldconsistentlybewillingtoagreeto?
Iftheproductweretocompeteatmarketratewhatwouldyousayistheaveragerate
weshouldexpecttocharge(ifthisdiffersfromthefairrateyoulistabove)?
Wouldyoubewillingtopayapremiumforlocalhops?
Ifyes,howmuchwouldyoubewillingtopayabovewhatyouarecurrentlypaying?10%,
20%,50%,100%,etc?
Ifyouwerewillingtopayapremiumforlocalhops,wouldthischangethevolumeof
localhopsyouwouldbuy(ieifyoupaymoreyoumightbuyless?)Isthissoandifso,
howwouldthevolumeoflocalhopsyoupurchasechange?
Whyareyouinterestedinbuyinghopslocally?
Areyouinterestedinorganichops?
Whatisthebestwaytocommunicatewithyou?
Otherthoughts/comments/suggestions?

2010
AppendixDCashFlowScenarios
Scenario1:GrowerparticipatingintheAtlanticHopsValueShareGrowerProgram,
Growing1Acre
Cashflow1:demonstratingcashflowifnoefficienciesinproductionareutilized
Cashflow2:demonstratingcashflowifgrowerharvestsonlytop1/3ofthebine
Cashflow3:demonstratingcashflowifgrowerharvestsonlytop1/3ofthebine,
andmanuallystripsandsorts
andmechanicallystripsandsorts

2010
Courtesy: Vermont Farm Viability Enhancement Program

CASH FLOW PROJECTION
Scenario: Participating in Atlantic Hops Value Share Grower Program
No Optimization in Harvesting
Projection
Production Information
Projection
Year 2
Year 1
Number of acres
Production Level
Quantity of dried hops sold (lbs/year)
Pounds of dried hops per acre per year
1
0%
0
0
9
Average price paid to grower per dried pound
Return on Investment in Years

Annual Net Income at 100% Production
Projection
Year 3
1
40%
600
600
9
Projection
Year 4
1
90%
1350
1350
9
1
100%
1500
1500
9
(2)
(9,610)
Cash Receipts
Hops Sold
5,400
TOTAL CASH RECEIPTS
5,400 $
13,500
12,150 $
12,150
13,500
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
610
610
23,110
$
$
$
$
610
610
23,110
$
$
$
$
610
610
23,110
$
$
$
$
610
610
23,110
Total Fixed Expenses
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
RECEIPTS MINUS EXPENSES
Cash Expenses
Variable Expenses:
Chemicals
Conservation expense
Custom hire
Trellising supplies- twine, w clips, etc.
Fertilizer
Fuel and oil
Labor hired (incl. FICA, workers comp, etc.)
Repairs, maintenance
Electricity for drying
Supplies
Sub total Variable Expenses
Labor
Spring/Summer Labor 500 hrs/acre @ $10/hr
Harvest Labor 1 hr/dried lb 1,500hrs @ $10/hr
Sub total Labor
Other Variable Expenses
Freight/Shipping estimating 2,000lbs NMFC classification 100
Other:
Sub total Other Variable Expenses
Total Variable Expenses:
Fixed Expenses:
Auto & truck
Interest, farm share
Insurance, farm share
Property tax, farm share
Rents paidland, buildings
Rents paidequipment, livestock
Utilities, farm share
Other:
Other:
Other:
Other:
23,110
(23,110) $
23,110
(17,710) $
23,110
(10,960) $
23,110
(9,610)
Plus CAPITAL CONTRIBUTIONS

grants
loans
off-farm income
other
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
10,000
10,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
$
$
$
$
$
(33,110) $
(55,820) $
(66,780)
(33,110) $
(55,820) $
(66,780) $
(76,390)
Plus CAPITAL SALES

equipment
Less CAPITAL EXPENSE

mechanical harvester
sorter
oast 1 phase, 3/4 hp
one acre hop yard- Atlantic Hops Value-Grower Set Price
Total Capital Expense
Less DEBT SERVICE

List Loan Principal Payments
Plus STARTING CASH
NET RETAINED CASH EARNINGS (DEFICIT)
- Income Taxes (estimate at 33%)

Less Family Living
- Capital Reserve
NET AFTER CAPITAL RESERVE, FAMILY LIVING AND

INCOME TAX ALLOCATION
$
$
(33,110) $
$
$
(55,820) $
$
$
(66,780) $
(76,390)

Optimized Manual Harvesting, Harvesting Only Top 1/3 of Bine
Projection
Projection
Year 2
Year 1
Number of acres
Production Level
1
0%
0
0
9

Projection
Year 3
1
40%
600
600
9
Projection
Year 4
1
90%
1350
1350
9
1
100%
1500
1500
9
(4)
(3,360)
Cash Receipts
Hops Sold
5,400
TOTAL CASH RECEIPTS
5,400 $
13,500
12,150 $
12,150
13,500
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
8,750
13,750
$
$
$
$
$
$
2,500
5,000
8,750
13,750
$
$
$
$
$
$
2,500
5,000
8,750
13,750
$
$
$
$
$
$
2,500
5,000
8,750
13,750
610
610
16,860
$
$
$
$
610
610
16,860
$
$
$
$
610
610
16,860
$
$
$
$
610
610
16,860
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
$
Sub total Variable Expenses $
Labor
$
$
Harvest Labor harvesting only top 1/3 of the bine 35 min/lb1,500lbs/acre (875 hrs) @ $10/hr
$
Sub total Labor $
$
Other:
$
Sub total Other Variable Expenses $
$
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
16,860
(16,860) $
16,860
(11,460) $
16,860
(4,710) $
16,860
(3,360)

grants
loans
off-farm income
other
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
10,000
10,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
$
$
$
$
$
(26,860) $
(43,320) $
(48,030)
(26,860) $
(43,320) $
(48,030) $
(51,390)
Plus CAPITAL SALES

equipment

sorter
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve
NET AFTER CAPITAL RESERVE, FAMILY LIVING AND INCOME TAX ALLOCATION
$
$
(26,860) $
$
$
(43,320) $
$
$
(48,030) $
(51,390)

Optimized Manual Harvesting, Harvesting Only Top 1/3 of Bine, Manual Stripping & Sorting
Projection
Projection
Year 2
Year 1
Number of acres
Production Level
1
0%
0
0
9

Projection
Year 3
1
40%
600
600
9
Projection
Year 4
1
90%
1350
1350
9
1
100%
1500
1500
9
38
390
Cash Receipts
Hops Sold
5,400
TOTAL CASH RECEIPTS
5,400 $
13,500
12,150 $
12,150
13,500
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
610
610
13,110
$
$
$
$
610
610
13,110
$
$
$
$
610
610
13,110
$
$
$
$
610
610
13,110
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
$
Labor
$
$
Harvest Labor harvesting top 1/3 of the bine, stripping and sorting 20 min/lb 1,500lbs/acre (500 hrs) @ $10/hr
$
Sub total Labor $
$
Other:
$
$
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
13,110
(13,110) $
13,110
(7,710) $
13,110
13,110
(960) $
390

grants
loans
off-farm income
other
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
10,000
10,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
$
$
$
$
$
(23,110) $
(35,820) $
(36,780)
(23,110) $
(35,820) $
(36,780) $
(36,390)
Plus CAPITAL SALES

equipment

sorter
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve
$
$
(23,110) $
$
$
(35,820) $
$
$
(36,780) $
(36,390)

Optimized Manual Harvesting, Harvesting Only Top 1/3 of Bine, Mechanized Stripping, Picking, & Sorting
Projection
Projection
Year 2
Year 1
Number of acres
Production Level
1
0%
0
0
9

Projection
Year 3
1
40%
600
600
9
Projection
Year 4
1
90%
1350
1350
9
1
100%
1500
1500
9
5
4,640
Cash Receipts
Hops Sold
5,400
12,150
13,500
TOTAL CASH RECEIPTS
5,400
12,150
13,500
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
610
610
8,860
$
$
$
$
610
610
8,860
$
$
$
$
610
610
8,860
$
$
$
$
610
610
8,860
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
8,860
8,860
8,860
8,860
(3,460) $
3,290
4,640
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
Harvest Labor harvesting only top 1/3 of the bine 3 min/lb- 1 min to pick, 2 min to sort 1,500lbs/acre (75 hrs) @ $10/hr
Sub total Labor
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
(8,860) $

grants
loans
off-farm income
other
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
10,000
10,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
5,000
5,000
10,000
$
$
$
$
$
Plus STARTING CASH
(18,860) $
(27,320) $
(34,030)
(18,860) $
(27,320) $
(34,030) $
(29,390)

Less Family Living
- Capital Reserve
(18,860) $
Plus CAPITAL SALES

equipment

sorter
oast
Less DEBT SERVICE

$
$
$
$
(27,320) $
$
$
(34,030) $
(29,390)

Scenario2:Growergrowinghopstosellaswholedriedhops

2010

Scenario: Selling Direct to Brewer, Whole Hops
Projection
Projection
Year 2
Year 1
Number of acres
Production Level
1
0%
0
0
15.51
10.00
Average price per dried pound needed to break even

Projected Sale Price to Brewers

Projection
Year 3
1
40%
600
600
16.11
10.00
Projection
Year 4
1
90%
1350
1350
16.11
10.00
1
100%
1500
1500
16.11
10.00
(2)
(9,160)
Cash Receipts
Hops Sold
6,000
13,500
15,000
TOTAL CASH RECEIPTS
6,000
13,500
15,000
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
$
$
610
150
760
23,260
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
24,160
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
24,160
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
24,160
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(23,260) $
(18,160) $
(10,660) $
(9,160)
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
$
$
$
$
$
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
$
$
$
$
Sub total Labor $

Chemical Analysis
Processing (pelletizing and packaging)
Climate Controlled Storage- rented climate controlled space
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
23,260
24,160
24,160
24,160

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

sorter
oast
one acre hop yard
Less DEBT SERVICE

Plus STARTING CASH
(35,260) $
(58,717) $
(69,674)
(35,260) $
(58,420) $
(69,377) $
(78,834)

Less Family Living
- Capital Reserve
297
-
297
-
(35,260) $
NET AFTER CAPITAL RESERVE, FAMILY LIVING AND INCOME TAX

ALLOCATION
$
$
$
$
(58,717) $
$
$
297
-
(69,674) $
(79,131)

Projection
1
0%
0
0
12.51
10.00


Projection
Year 2
Year 1
Number of acres
Production Level
Projection
Year 3
1
40%
600
600
13.11
10.00
Projection
Year 4
1
90%
1350
1350
13.11
10.00
1
100%
1500
1500
13.11
10.00
(4)
(4,660)
Cash Receipts
Hops Sold
6,000
13,500
15,000
TOTAL CASH RECEIPTS
6,000
13,500
15,000
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
610
150
-
$
$
$
760
18,760
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
19,660
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
19,660
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
19,660
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(18,760) $
(13,660) $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
$
$
$
$
$
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
Harvest Labor harvesting only top 1/3 of the bine 35 min/lb1,500lbs/acre @ $10/hr
Sub total Labor
Chemical Analysis
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
18,760
19,660
19,660
(6,160) $
19,660
(4,660)

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

sorter
oast
one acre hop yard
Less DEBT SERVICE

Plus STARTING CASH
(30,760) $
(49,717) $
(56,174)
(30,760) $
(49,420) $
(55,877) $
(60,834)

Less Family Living
- Capital Reserve
297
-
297
-
(30,760) $

ALLOCATION
$
$
$
$
(49,717) $
$
$
297
-
(56,174) $
(61,131)

Projection
Number of acres
Production Level
1
0%
0
0
8.84
10.00


Projection
Year 2
Year 1
Projection
Year 3
1
40%
600
600
9.44
10.00
Projection
Year 4
1
90%
1350
1350
9.44
10.00
1
100%
1500
1500
9.44
10.00
26
840
Cash Receipts
Hops Sold
6,000
13,500
15,000
TOTAL CASH RECEIPTS
6,000
13,500
15,000
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
610
150
760
13,260
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
14,160
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
14,160
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
14,160
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
$
Labor
$
$
$
Sub total Labor $
$
Chemical Analysis
$
$
$
Sales & Marketing
Other:
$
$
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(13,260) $
13,260
14,160
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
5,000
5,000
$
$
$
$
$
Plus STARTING CASH
(25,260) $
(38,717) $
(44,674)
(25,260) $
(38,420) $
(44,377) $
(43,834)

Less Family Living
- Capital Reserve
297
-
297
-
(25,260) $
(8,160) $
14,160
14,160
(660) $
840

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

sorter
oast
one acre hop yard
Less DEBT SERVICE

$
$
$
$
(38,717) $
$
$
297
-
(44,674) $
(44,131)

Scenario: Selling Direct To Brewer, Whole Hops
Projection
1
0%
0
0
6.01
10.00


Projection
Year 2
Year 1
Number of acres
Production Level
Projection
Year 3
1
40%
600
600
6.61
10.00
Projection
Year 4
1
90%
1350
1350
6.61
10.00
1
100%
1500
1500
6.61
10.00
5
5,090
Cash Receipts
Hops Sold
TOTAL CASH RECEIPTS
6,000
6,000 $
13,500 $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
610
150
760
9,010
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
9,910
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
9,910
$
$
$
$
$
$
$
$
610
150
100
700
100
1,660
9,910
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
9,010
9,910
9,910
9,910
(3,910) $
3,590
5,090
13,500
15,000
15,000
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
$
Labor
$
$
$
Sub total Labor $
$
Chemical Analysis
$
$
$
Sales & Marketing
Other:
$
$
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
(9,010) $

grants
loans
off-farm income
other
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
5,000
5,000
10,000
$
$
$
$
$
(21,010) $
(30,217) $
(36,924)
(21,010) $
(29,920) $
(36,627) $
(31,834)
297
-
297
-
Plus CAPITAL SALES

equipment

sorter
oast
one acre hop yard
$
$
5,000 $
$
5,000 $
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve
$
$
(21,010) $
$
$
(30,217) $
$
$
297
-
(36,924) $
(32,131)

Scenario3:GrowersendinghopstoAtlanticHopsforprocessing

2010

Scenario: Selling Pelletized Direct To Brewer Using Atlantic Hops Processing Services
Projection
Projection
Year 2
Year 1
Number of acres
Production Level
Projected Sale Price
1
0%
0
0
15.00
15.00

Projection
Year 3
1
40%
600
600
17.81
15.00
Projection
Year 4
1
90%
1350
1350
20.56
15.00
1
100%
1500
1500
21.11
15.00
(2)
(9,160)
Cash Receipts
Hops Sold
9,000
20,250
22,500
TOTAL CASH RECEIPTS
9,000
20,250
22,500
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
$
$
$
2,500
5,000
15,000
20,000
$
$
$
610
150
3,300
$
$
$
610
150
7,425
$
$
$
610
150
8,250
$
$
$
22,500
$
$
$
$
$
50
100
4,210
26,710
$
$
$
$
$
50
100
8,335
30,835
$
$
$
$
$
50
100
9,160
31,660
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(22,500) $
(17,710) $
(10,585) $
(9,160)
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
$
2,000
5,000
7,000
$
$
$
$
$
$
$
$
$
$
$
$
(34,500) $
(59,210) $
(69,795)
(34,500) $
(59,210) $
(69,795) $
(78,955)
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
$
$
$
$
Sub total Labor $

Chemical Analysis
Processing (pelletizing)
Packaging
Climate Controlled Storage
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
$
$
$
22,500
26,710
30,835
31,660

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

2 chest freezers
sorter
oast
one acre hop yard
Less DEBT SERVICE

Plus STARTING CASH
- Income Taxes
Less Family Living
- Capital Reserve

ALLOCATION
(34,500) $
(59,210) $
(69,795) $
(78,955)

Projection
Number of acres
Production Level

Projection
Year 2
Year 1
1
0%
0
0
12.51
15.00
Projection
Year 3
1
40%
600
600
14.81
15.00
Projection
Year 4
1
90%
1350
1350
17.56
15.00
1
100%
1500
1500
18.11
15.00
(4)
(4,660)
Cash Receipts
Hops Sold
9,000
20,250
22,500
TOTAL CASH RECEIPTS
9,000
20,250
22,500
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
$
$
2,500
5,000
10,500
15,500
$
$
$
$
610
150
-
$
$
$
760
18,760
$
$
$
$
$
$
$
$
$
610
150
3,300
50
100
4,210
22,210
$
$
$
$
$
$
$
$
$
610
150
7,425
50
100
8,335
26,335
$
$
$
$
$
$
$
$
$
610
150
8,250
50
100
9,160
27,160
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(18,760) $
(13,210) $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
$
2,000
5,000
7,000
$
$
$
$
$
$
$
$
$
$
$
$
(30,760) $
(52,109) $
(60,693)
(30,760) $
(50,970) $
(58,194) $
(65,353)
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
Sub total Labor
Chemical Analysis
Packaging
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
18,760
22,210
26,335
(6,085) $
27,160
(4,660)

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

2 chest freezers
sorter
oast
one acre hop yard
$
$
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve

ALLOCATION
$
$
(30,760) $
1,139
-
$
$
(52,109) $
2,500
-
$
$
(60,693) $
2,772
-
(68,125)

Projection
Number of acres
Production Level

Projection
Year 2
Year 1
1
0%
0
0
8.84
15.00
Projection
Year 3
1
40%
600
600
11.14
15.00
Projection
Year 4
1
90%
1350
1350
13.89
15.00
1
100%
1500
1500
14.44
15.00
29
840
Cash Receipts
Hops Sold
9,000
20,250
22,500
TOTAL CASH RECEIPTS
9,000
20,250
22,500
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
$
$
$
2,500
5,000
5,000
10,000
$
$
$
610
150
-
$
$
$
760
13,260
$
$
$
$
$
$
$
$
$
610
150
3,300
50
100
4,210
16,710
$
$
$
$
$
$
$
$
$
610
150
7,425
50
100
8,335
20,835
$
$
$
$
$
$
$
$
$
610
150
8,250
50
100
9,160
21,660
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(13,260) $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
$
2,000
5,000
7,000
$
$
$
$
$
$
5,000
5,000
$
$
$
$
$
$
(25,260) $
(41,109) $
(49,193)
(25,260) $
(39,970) $
(46,694) $
(48,353)
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
Sub total Labor
Chemical Analysis
Packaging
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
13,260
16,710
(7,710) $
20,835
21,660
(585) $
840

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

2 chest freezers
sorter
oast
one acre hop yard
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve
$
$
(25,260) $
1,139
-
$
$
(41,109) $
2,500
-
$
$
(49,193) $
2,772
-
(51,125)

Projection
1
0%
0
0
6.01
15.00


Projection
Year 2
Year 1
Number of acres
Production Level
Projection
Year 3
1
40%
600
600
8.31
15.00
Projection
Year 4
1
90%
1350
1350
11.06
15.00
1
100%
1500
1500
11.61
15.00
6
5,090
Cash Receipts
Hops Sold
TOTAL CASH RECEIPTS
9,000
9,000 $
20,250 $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
610
150
-
$
$
$
760
9,010
$
$
$
$
$
$
$
$
$
610
150
3,300
50
100
4,210
12,460
$
$
$
$
$
$
$
$
$
610
150
7,425
50
100
8,335
16,585
$
$
$
$
$
$
$
$
$
610
150
8,250
50
100
9,160
17,410
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
9,010
20,250
22,500
22,500
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
Sub total Labor
Chemical Analysis
Packaging
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
(9,010) $
12,460
16,585
17,410
(3,460) $
3,665
5,090

grants
loans
off-farm income
other
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000
12,000
$
$
$
$
$
$
2,000 $
$
$
5,000 $
$
7,000 $
5,000
5,000
10,000
$
$
$
$
$
$
Plus STARTING CASH
(21,010) $
(32,609) $
(41,443)
(21,010) $
(31,470) $
(38,944) $
(36,353)

Less Family Living
- Capital Reserve
1,139
-
2,500
-
Plus CAPITAL SALES

equipment

2 chest freezers
sorter
oast
one acre hop yard
Less DEBT SERVICE

$
$
(21,010) $
$
$
(32,609) $
$
$
2,772
-
(41,443) $
(39,125)
Scenario4:Growersellspelletizedhopsdirecttobrewer,usingDoItYourself
pelletizing

2010

Scenario: Selling Direct to Brewer D-I-Y Pelletized
Projection
Projection
Year 2
Year 1
Number of acres
Production Level
1
0%
0
0
15.51
15.00


Projection
Year 3
1
40%
600
600
15.89
15.00
Projection
Year 4
1
90%
1350
1350
15.89
15.00
1
100%
1500
1500
15.89
15.00
(35.15)
(1,340)
Cash Receipts
Hops Sold
TOTAL CASH RECEIPTS
9,000
9,000 $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
20,250 $
20,250
22,500
22,500
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
$
$
$
$
Sub total Labor $

Chemical Analysis
Packaging
Sales & Marketing
Other:
$
2,500 $
$
5,000 $
15,000 $
20,000 $
$
$
$
$
$
$
$
$
$
2,500 $
$
5,000 $
15,000 $
20,000 $
$
2,500 $
$
5,000 $
15,000 $
20,000 $
2,500
5,000
15,000
20,000
610
150
100
330
50
100
1,340
23,840
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
23,840
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
23,840
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
610
150
-
$
$
$
760
23,260
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(23,260) $
(14,840) $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,000
24,000
2,400
1,700
5,000
35,100
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
23,260
23,840
23,840
(3,590) $
23,840
(1,340)

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

2 chest freezers
vacuum, nitrogen flush sealer
pellet mill
hammer mill
sorter
oast
one acre hop yard
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000 $
12,000 $
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve

ALLOCATION
(35,260) $
(85,391) $
(89,173)
(35,260) $
(85,200) $
(88,981) $
(90,513)
191
-
191
-
$
$
(35,260) $
$
$
(85,391) $
$
$
191
-
(89,173) $
(90,704)

Projection
1
0%
0
0
12.51
15.00


Projection
Year 2
Year 1
Number of acres
Production Level
Projection
Year 3
1
40%
600
600
12.89
15.00
Projection
Year 4
1
90%
1350
1350
12.89
15.00
1
100%
1500
1500
12.89
15.00
14.91
3,160
Cash Receipts
Hops Sold
TOTAL CASH RECEIPTS
9,000
9,000 $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
20,250 $
20,250
22,500
22,500
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
$
$
$
$
$
$
$
2,500 $
$
5,000 $
10,500 $
15,500 $
$
$
$
610
150
-
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES

Labor
Sub total Labor
Chemical Analysis
Packaging
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
$
$
$
$
$
$
$
$
$
2,500 $
$
5,000 $
10,500 $
15,500 $
$
2,500 $
$
5,000 $
10,500 $
15,500 $
2,500
5,000
10,500
15,500
760
18,760
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
19,340
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
19,340
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
19,340
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
18,760
19,340
19,340
19,340
(18,760) $
(10,340) $
910
3,160
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,000
24,000
2,400
1,700
5,000
35,100
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

2 chest freezers
pellet mill
hammer mill
sorter
oast
one acre hop yard
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000 $
12,000 $
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve

ALLOCATION
(30,760) $
(76,391) $
(75,673)
(30,760) $
(76,200) $
(75,481) $
(72,513)
191
-
191
-
$
$
(30,760) $
$
$
(76,391) $
$
$
191
-
(75,673) $
(72,704)

Projection
1
0%
0
0
8.84
15.00


Projection
Year 2
Year 1
Number of acres
Production Level
Projection
Year 3
1
40%
600
600
9.23
15.00
Projection
Year 4
1
90%
1350
1350
9.23
15.00
1
100%
1500
1500
9.23
15.00
5.44
8,660
Cash Receipts
Hops Sold
TOTAL CASH RECEIPTS
9,000
9,000 $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
20,250 $
20,250
22,500
22,500
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
$
$
$
$
$
$
$
2,500 $
$
5,000 $
5,000 $
10,000 $
$
$
$
610
150
-
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
(13,260) $
$
$
$
$
$
$
$
$

Labor
Sub total Labor
Chemical Analysis
Packaging
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
$
$
$
$
$
$
$
$
$
2,500 $
$
5,000 $
5,000 $
10,000 $
$
2,500 $
$
5,000 $
5,000 $
10,000 $
2,500
5,000
5,000
10,000
760
13,260
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
13,840
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
13,840
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
13,840
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
13,260
13,840
13,840
13,840
(4,840) $
6,410
8,660
$
$
$
$
$
$
$
$
2,000
24,000
2,400
1,700
5,000
35,100
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$

grants
loans
off-farm income
other
Plus CAPITAL SALES

equipment

2 chest freezers
pellet mill
hammer mill
sorter
oast
one acre hop yard
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000 $
12,000 $
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve
(25,260) $
(65,391) $
(59,173)
(25,260) $
(65,200) $
(58,981) $
(50,513)
191
-
191
-
$
$
(25,260) $
$
$
(65,391) $
$
$
191
-
(59,173) $
(50,704)

Scenario: Selling Direct To Brewer D-I-Y Pelletized
Projection
1
0%
0
0
6.01
15.00


Projection
Year 2
Year 1
Number of acres
Production Level
Projection
Year 3
1
40%
600
600
6.39
15.00
Projection
Year 4
1
90%
1350
1350
6.39
15.00
1
100%
1500
1500
6.39
15.00
4
12,910
Cash Receipts
Hops Sold
TOTAL CASH RECEIPTS
9,000
9,000 $
20,250 $
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
$
$
$
2,500
5,000
750
5,750
$
$
$
610
150
-
$
$
$
760
9,010
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
9,590
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
9,590
$
$
$
$
$
$
$
$
$
610
150
100
330
50
100
1,340
9,590
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
TOTAL CASH EXPENSES
9,010
9,590
9,590
9,590
(590) $
10,660
12,910
20,250
22,500
22,500
Cash Expenses
Variable Expenses:
Chemicals
Custom hire
Fertilizer
Fuel and oil
Supplies
Labor
Sub total Labor
Chemical Analysis
Packaging
Sales & Marketing
Other:
Fixed Expenses:
Auto & truck
Other:
Other:
Other:
Other:
(9,010) $

grants
loans
off-farm income
other
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
5,000
5,000
10,000
$
$
$
$
$
$
$
$
$
Plus CAPITAL SALES

equipment

2 chest freezers
pellet mill
hammer mill
sorter
oast
one acre hop yard
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
12,000 $
12,000 $
2,000 $
24,000 $
2,400 $
1,700 $
$
$
5,000 $
$
35,100 $
Less DEBT SERVICE

Plus STARTING CASH

Less Family Living
- Capital Reserve
(21,010) $
(56,891) $
(56,423)
(21,010) $
(56,700) $
(56,231) $
(43,513)
191
-
191
-
$
$
(21,010) $
$
$
(56,891) $
$
$
191
-
(56,423) $
(43,704)
AppendixESampleHopyardDesigns
1. HopyardDesignfromCranngAles,LeftFields
CrannogAlesHopsUpdate,2007
RebeccaKneen
Hopyardsize:1acre,209'/side
Plants
Poles
Beds
spacing
(foot)
per
bedor
row(#)
Total
ea
Cable
main
3.5
25
15
25
Cable
seconda
ry
3.5
60
900
81
3,762
12,540
Obviously,considerablevariationcanbeexpectedwithcleveruseofscrounged
materialsorfoundmaterials.
AnnualActivities
Crowningordiggingrhizomes
Irrigationmaintenance
Topdressingwithcompost
Mulchingplants
Stringingplants
Covercrop/greenmanuremaintenance
Inspections/cleanupandIPM
Harvest&packaging
Alloftheseactivitiestakepersonhoursandmachineryofsomedescription,whether
it'syourpocketknifeormorecomplextools.Themajoractivitiestakeplaceinearly
spring,assoonasthegroundisopen,andinthefallatharvest.Wefindthatittakes
25persondaystodigrhizomesover1/2acrebutifyouareonlyrootpruning
ratherthandiggingrhizomes,thistimewouldbecutbyatleasthalfifnot3/4.
Stringingtimedependsontheefficiencyofyoursystem.Byfarthemostcost
effectivemethodonlargerholdingsistouseacherrypickerorsomesuchdeviceto
rundowntherows,tyingstringstothetrellisingateachplant,followedbyaground
personanchoringthestringsandtwiningthevines.Summerworkisrelativelylight,

2010
dependingonyourweedcontrolmethodologyandIntegratedPestManagement
(IPM)use.Harvestandpackaging
varywidely,withconsiderationsincludinguseofmachinerytoharvestandtopull
plantsdown,speedofhandpickersanddryerefficiency.
Itshouldbeclearfromthisthatthereisconsiderablepotentialinorganichops
production.Westronglyrecommendsmallscaleproductionforthenewgrowerand
directliaisonwithyourbrewerycustomers.Capitalcostscanbeamortizedoverthe
lifetimeoftheyard,withpolesbeingreplacedasneededduringthattime.Agroup
ofsmallhopgrowerscanalsotakeadvantageofgroupdryersandvacuumsealers,
aswellascreatingatrainedandmobileworkforce.
2. HopyardDesignfromHopyardConstruction:BudgetingandEconomics
EdwardB.Page,Ph.D.CSUExtension
RonGodin,Ph.D.CSUAgExp.Station
Hopyard
18to20high
Plantspacing7x7
Population:889
21posts
2to3inground
Variousspacings
14x42
15x30
30x30
Equilateraltriangleatendposts
15base
Polesconnectedwithinrowsonly
Toptrainingwireisfreefloating
Highlaborinput
Highproduction
Methodology
SteelAnchorEmbeddedinConcrete
Newaugertypeanchors(notforsandysoils)
WireClampforAnchorWire
ClampingCable
Cornerendwithtripleanchors
HopGrowthonHighTrellis
Coirtwineistiedtoclipplacedinsoilnexttohill
Twineistiedtotopwire

2010
Trainedhopvinewindsitswaytotop
Harvesting:cutstopandbottomandremoveforpicking&processing
3. HopyardDesignfromUVMExtension
RosalieMadden,HeatherDarby,RogerRainville
PerAcre(60x660)
1320bines
3360Rowsspaced20apart,1rowevery10oneithersideofapole.
Thenwithintherow,2rhizomesperhill,maintainatleastatleast3.5
betweenhills,andatleast7(15isbetter)betweenvarieties,40
rhizomesperrowx33rows.
TypicalspacinginthePacificNWisbetween4250sqftperplant,witha
spacingofeither3.5x14,or7x7,forapproximately900bines/ac.1
1102024poles
1poleevery20ft
45plantsperpole
Notethatgeneralpolespacingrecommendationsare30x30,or30x15,
or14x42.UVMspacedtheirsat20x35becauseitmadeiteasierto
delineatebetweenvarietiesandrepetitionsfortrialingpurposes.2
110postprotectionplatesmetalplatestoprotectthepoles
Maincabletobestrungbetweenpoles2,178of3/8steelcable(~3rowsof
660)
Anchor,clampsandwireholdingpoles(2anchorsand40cableperpole)
Wireevery10betweenthethreerows(3,960)
Hopstringertrailerorsomemechanismsuchasaforklift,bucketloader,back
ofpickuptruck,orladders,togetpeoplehighenoughoffthegroundtostring
thewireandthecoirtwine.
1
2
InformationprovidedbyRosalieMadden,UVMExtension,July2010.
InformationprovidedbyRosalieMadden,UVMExtension,July2010.

2010
4. HighDensityHopyardDesignfromGorstValley
JamesAltwies
PerAcre
TrellisMaterials
Structure
Qty
Units
EndPoles 22
each
LinePoles 66
each
Deadmen 26
each
Supplies
Qty
Units
Droplines 1283
Clover 20
Rhizomes 1283
Hardware
Qty
Turnbuckles 22
eyebolts 132
3/16GAC 4235
1/4GAC 484
3/16clips 44
1/4clips 88
3/16thimb 22
1/4thimb 44
lowline 4235
IrrigationMaterials
IrrigationTube
Dripline
Valves
Mainline
Branchline
Tees
1.25"x1.25"x1.25
"
1.25"x0.5"x1.25"
Couplers
0.5"x0.5"
EndCaps
0.5"
HoseClamps
0.5"1.0"
Distrb.&Control
Pump
Filter
Controller
Sensors
Shutoffvalve
Checkvalve
5strandwire
Valvebox
each
lbs
each
Units
each
each
lin.Ft
lin.Ft
each
each
each
each
lin.Ft

2010
Qty
4235
2
200
500
Qty
1
11
Qty
10
Qty
11
Qty
20
Qty
1
1
1
1
1
1
250
2
Units
lin.Ft
each
lin.Ft
lin.Ft
Units
each
each
Units
each
Units
each
Units
each
Units
each
each
each
each
each
each
lin.Ft
each
AppendixFHopyardEstablishmentCostsPerAcre
Samplebudgetsfrom:
CrannogAles
EdwardB.PageandGlennFuller,ColoradoExtension
UniversityofVermontExtension
GorstValleyHopsValueShareGrowerProgram

2010
HighDensityGorstValleyHopyardStandardTrellisEstablishmentCostperAcre
HopyardStandardTrellisEstablishmentCostperAcre
DataCourtesyofJamesAltwies
DataCourtesyofGlenFuller(Colorado)
Rhizomes(4x12)
Misc.Hardware&Supplies
Trellis Materials
Structure
Qty
Units
End Poles
22
each
Line Poles
66
each
Deadmen
26
each
Poles(21untreated,lodgepolepine)
Sub Total Structure $
2,942
Supplies
Droplines
Clover
Rhizomes
1283
each
20
lbs
1283
each
444
Hardware
Turnbuckles
22
each
eyebolts
132
each
3/16 GAC
4235
lin. Ft
1/4 GAC
484
lin. Ft
3/16 clips
44
each
1/4 clips
88
each
3/16 thimb
1/4 thimb
lowline
22
each
lin. Ft
1,394
Irrigation Tube
Dripline
4235
lin. Ft
Valves
each
Main line
200
lin. Ft
Branch line
500
lin. Ft
tees 1.25"x1.25"x1.25"
each
tees 1.25"x0.5"x1.25"
11
each
Couplers 0.5"x0.5"
10
each
End caps 0.5"
11
each
Hose clamps 0.5"-1.0"
20
each
Pump
each
Filter
each
Controller
each
Sensors
each
Shut-off valve
Check valve
each
5 strand wire
250
lin. Ft
each
Distrb. & Control
DataCourtesyRosalieMadden,RogerRainville
Pots(6square)
5000
0.46 $2,300
$600
Misc.Hardware&Supplies
BobCat&Auger(holesforpoles)
$550
Poles(21untreated,lodgepolepine)
7StrandWire(carriesfloatingwires)
$800
D5DozerWork
#9Wire(floatingtopwire)
$250
BobCat&Auger(holesforpoles)
$2,150
HopTwine(coir:coconuthuskfiber)
$140
7StrandWire(carrieshopwires)
$3,146
#9Wire(floatingtopwire)
$997
$556
48
8.33 $400
22ftlocustpoles
22ftcedarpoles
$5,026
210
20.38 $4,280
$2,400
DripIrrigationMaterials
$1,500
HopTwine(coir:coconuthuskfiber)
30hrs.Tilling
$300
48GroundAnchors
40hrs.PoleSetting
Gallows(forworkontopwires)
$400
$140
DripIrrigationMaterials
30hrs.Tilling
$5,980
$1,200
Labor
TotalEstablishmentCost
EstablishmentCostNotIncludingLaborper
Acre
$3,750
$12,420
$8,670
40hrs.PoleSetting
Gallows(forworkontopwires)
Labor
$1,600
$556
$15,000
TotalEstablishmentCost
EstablishmentCostperAcre
EstablishmentCostNotIncludingLaborperAcre
$52,561
$13,140
$9,390
188
8.4 $1,580
Each
Sum
Poles
30
42 $1,260
53
25 $1,325
SubtotalPoles
5/16"x5000ft
$1,733
5/16"x1000ft
$347
$107
5/16"x250ft
3/8"x500ft
$280
3/4"x12eye/hookturnbuckle
34
15.92 $721
cablecutters
5/16"x10pcsforgedw/rclips
1
200
$66
0.64 $171
5x46anchor
50
50
40
0.94 $63
0.94 $25
9 $360
Earthaugeranchor,5"x46"
Screws
2HavenGripscablepullers
40
5 $267
$159
$166
Supplies
10yardsstone
LeftFieldsHopyardStandardTrellisEstablishmentCostperAcre
RebeccaKneen
Qty
$/Unit
$Total
Cranng Ales, Left Fields
Poles
81
25
2,025
CablingPrimary
CableSecondary
String2/plant
Anchors,cable
Rhizomesfreshhops/hopsunionbulkprice
3762
12540
1800
26
0.4
0.26
0.02
9
1,505
3,260
36
234
Cableclamps
passthroughs(loops)
Cableeyes
KleinHavenGrip
194
63
26
1
0.29
1.5
0.32
160
56
95
8
160
Rhizomes
Total
900
3.5
3150
10,529
1,274
2,053
150 hrs
1,500
50 hrs
500
10,107
8,107
2,585
Wire
DripIrrigationSuppliesandInstallation
SubtotalSupplies
Labor
Digtestholes
1,778rhyzomes
2/hill
4,465
$460
3 $5,334
$
$ 5,794
$30
Installpoles,digging,stone,2tractors&loader
Installpoles,labor
setpoles,labor
tractoranddumpwagon
18
25
5
9.5
10
10
10
10
$180
$250
$50
$95
labor
tractorandaugertosetanchors
labortosetanchors
tractorandlift
till
Plantrhyzomes
tractorandloadertosetpoles
Tractorandaugertosetanchors
65
4
2
32
4
16
13
3
10
10
10
10
10
10
10
10
$650
$40
$20
$320
$40
$160
$130
$30
SubtotalLabor
Sub Total Irrigation $
EstablishmentCostperAcre
EstablishmentCostNotIncludingLaborperAcre
1.21 $5,040
$750
each
Plants
Machine Hours
20.57 $1,070
4160
SubtotalWire
Sub Total Hardware $
Labor
52
UVMExtensionHopyardstandardizedto1acre
ByEdwardB.Page,DataCourtesyofGlenFuller
Rhizomes
PottingSoil
each
44
4235
Irrigation Materials
Valve box
1.21 $1,260
$1,260
D5DozerWork
48GroundAnchors
Sub Total Supplies $
StandardTrellisEstablishmenton4Acres
1040
EquipmentRent
transportdigger
rentrototiller
rentalforpoledigger
SubtotalEquipmentRent
TotalHopYardCostPerAcre
TotalHopYardCostPerAcreNotIncludingLabor
TotalHopYardCostPerAcreEstimating$20/poleandNotIncludingLabor
1,995
$150
$88
$339
$
577
$15,416
$13,421
$12,496
AppendixGLaboratoryAnalysisServiceProviders
BrewingandDistillingAnalyticalServices,LLC(BDAS,LLC)
128ShadyLane
Lexington,KY40503
Tel:8592782533
http://www.alcbevtesting.com/
BDASpartnerswithTomShelhammeratOregonStateUniversitytoofferthefollowing
analyses
Oils(CohumuloneandHumulone)
HPLChighperformanceliquidchromatographytest $100/sample
AlphaandBetaAcids
tolueneextractiontest
$50/sample
ReducedAlphaAcidsforlightstruckprevention
Lightstruckpreventiontest
$100/sample
(forclearbottledbeer,tostudyhopsthatmightreacttolight)Coronaclear
bottleshaveaskunkysmellbutMillerclearbottlesdonotandthisisbecause
Millerspeciallyselectshopsbredtobelightstruckreduced
BrewLaboratory
J.Frizzell
18223CrestviewCircle
Holt,MO64048
[email protected]
BrewLaboratoryisofferingaHighPerformanceLiquidChromatographic(HPLC)analysis
ofyourwholeleaforpellethopsfor:
AlphaAcid%(cohumuloneandadhumulone+humulone)
BetaAcid%(colupuloneandadlupulone+lupulone)
Cohumulone%(%cohumulonecontributesofthetotalAlphaAcid%)
Wewillanalyzeyourhopsfor$24.00persample.
SiebelInstituteofTechnology
LaboratoryServices
HeadOffice:1777NClybournAvenueChicago,IL60614
Phone:3122550705Fax:3122551312
EMail:laboratory@siebelinstitutecom
Web:wwwsiebelinstitutecom
Sampledeliveryonly:
SiebelLaboratories
7564TradeStreet

2010
SanDiego,CA92121,USA
(888)5932785
HOPANALYSES
Options
#3000Moisture(Internationalmethod)
#3010Alphaacids(spectrophotometric)
#3020Alphaacids(conductometric)
#3030Alphaandbetaacids(HPLC)
#3060HopOilProfile(GC)
#3070HopTeaFlavorEvaluation
#3080Humulene2ol
#3090Iso,tetra,dihydro,hexahumulones
#3100Nitrate(HPLC)
#3110TotalEssentialOils
#3120VarietyProfile(truenesstotype)
Allindividualanalysis/otheranalysis
Price$
22
55
65
131
158
89
110
POR
POR
23
POR
POR

2010
Quantity
200gpellets
200gpellets
200gpellets
200gpellets
200gpellets
200gpellets
200gpellets
200gpellets
200gpellets
200gpellets
200gpellets
AppendixHExpiredHopHarvesterPatents
HighTrellisPatents
MobilePatents
LowTrellisPatent

2010
AppendixIFujiImpulseNitrogenFlushVacuumSealerProductInformation

2010
Printed JUL 2009

3rd Edition 3.02E
Microcomputer-controlled
Nozzle-type vacuum / gas flushing sealer
VG
- 602
- 402
series
Operating Instructions
110/220V Specification
VG-602/402 series Operating Instructions Ver. 3.02E
Thank you for your purchasing of VG-602/402 series sealer.

VG-602/402 series sealer is microcomputer controlled.
This model has the specification in which various set up is possible.
So there are many things that the customer should understand at the beginning of use.
This manual has explanation of terms and reference function like a dictionary.
Please utilize the manual, and understand the following matters.
1. Set up the pattern of operation.

Two patterns sealing method is set at the
shipping from manufacture's factory.
But please set up the sealing condition as you

need at first.
If set up would not be done, you could not use
except standard patterns.
Set up is easy if you proceed in according to
this manual.
2. Verification and setting of optimum value.

There are various pattern of package material
and content in customer's use environment.
Please set the optimum value in heating

temperature, time, cooling temperature,
Vacuum time, degree which matches your
needs after the sufficient test and verification.
Please refer to the following table.
It shows the temperature of dissolution.
But this value is influenced by the
environment, thickness of package material
and other condition.
Kind of packing
material
HDPE
HPLDPE
LLDPE
PP
Temperature of
dissolution (OF)
266-275
221-248
248-266
320
Kind of packing
material
HDPE
HPLDPE
LLDPE
PP
Temperature of
dissolution (OC)
130-135
105-120
120-130
160
Foreword
Please read all of the safety and operating instructions before operating this machine. Periodic maintenance
and proper operation are necessary to ensure safety when using this impulse sealer.
Keep this manual on hand when operating the sealer.
Set the heating time according to the material and thickness of the film.
As a result of research to further improve, some details in the operating instructions may differ from your
actual machine. For operating problems or product information, please contact your local dealer or Fuji
Impulse.
About the warning labels

The following marks are used in this manual to
easily identify the conditions of risks, damages, or
some tips for the optimal use of your unit.
Minor injuries or damages to the unit
may occur when the instruction is ignored.
Caution
Severe injuries or fatal accidents may

occur when the instruction is ignored.
Warning
Critical injuries or fatal accidents will

almost certainly occur when the instruction is ignored.
Danger
Important Notes and Restrictions Read the directions in order to avoid

misuse of the unit.
TIPS
Great Tips and References when using the unit - Highly recommend reading through the information.
Attention
SI units
The International System of
Units (SI) is a consistent
system that ordinary people as
well as professionals can use.
This logical unit system is used

in every field from science to
industry to education and even
daily life.
As the SI unit system is
gradually replacing the
This manual is designed to

cover machines of various
voltages and plug
configurations
Before using, always verify the voltage
specification of your particular unit and operate it
at the correct voltage.
Please note the following:
1) The voltage specification of your unit is
listed on the label (or in some cases an
aluminum plate) which displays the serial
number. This label can be found on the
machine body.
2) The explanations and illustrations in this
operators' manual utilize the following
standard plug configurations most common
in Japan. However, due to the various
configurations in use worldwide, these may

not necessarily correspond with the one
attached to your specific unit.
Torr
mmHg
760
700
100
0
-0.01-10
-0.02-20
600
200
500
300
400
400
-0.03-30
-0.04-40
-0.05-50
-0.06-60
300
500
200
600
100
700
0
MPakPa
760
-0.07-70
-0.08-80
-0.09-90
-0.1-100
100V
15A
Warning
200V
20A
100V
20A
200V
30A
100V
20A30A
Voltages and plug configurations

differ according to various worldwide
specifications.
A verify those of your particular unit
before beginning operation.
Connecting the power cord to an
outlet of a different specification is
extremely hazardous.
standard pressure unit, this manual primarily uses

SI to indicate pressure. (As a reference, however,
we have also listed the previous notations.)
Table of Contents
1 Package contents................................................................................................. 7
2 Warning-Caution label location and content...................................................... 8
3 Operating precautions....................................................................................... 10
3-1 For safety operating............................................................................................................................. 10
3-2 For smooth operation........................................................................................................................... 13
3-3 Other safeguards................................................................................................................................. 13
4 Outline of structure............................................................................................ 14
5 Purpose usage of the sealer.............................................................................. 14
6 Major parts and function................................................................................... 15
7 Preparation.......................................................................................................... 16
7-1 Securing the work place....................................................................................................................... 16
7-2 Connect the power source .................................................................................................................. 16
7-3 Installing the foot switch....................................................................................................................... 17
7-4 Adjusting the height and angle of the table.......................................................................................... 17
7-5 Check the dry filter............................................................................................................................... 18
7-6 Cleaning by the weeping valve............................................................................................................. 18
7-7 Taking water by the drain hose............................................................................................................. 18
7-8 Adjusting the nozzle position................................................................................................................ 18
7-9 Adjusting the angle of sealing area...................................................................................................... 19
7-10 Emergency stop switch...................................................................................................................... 20
7-11 Attaching the gas tank and gas adjuster............................................................................................ 20
8 Proper use of the sealer..................................................................................... 21

8-1 Operation by the initial set up = Standard operation............................................................................ 22
Sealing only.....................................................................................................................................................23
Vacuum and seal - Operator decide the finish of vacuum by seeing...............................................................24
Gas flushing and seal - by initial set up vacuum and gas flushing time..............................................................26
Two times gas flushing and seal - by initial set up vacuum and gas flushing time..........................................28
8-2 Entry..................................................................................................................................................... 30
Entry for sealing only.......................................................................................................................................31
Entry for 1 time vacuum and gas flushing by timer..........................................................................................32
8-3 Explanation of the terms...................................................................................................................... 33

8-4 Reference............................................................................................................................................. 34
For operation...................................................................................................................................................34
For set-up........................................................................................................................................................35
8-5 Operation procedure............................................................................................................................ 52

Sealing only.....................................................................................................................................................52
Vacuum (manual) and Sealing........................................................................................................................54
Vacuum (timer) and Sealing............................................................................................................................56
Vacuum (gauge) and Sealing..........................................................................................................................58
[1 time] Vacuum (manual), Gas flushing and Sealing......................................................................................60
[1 time] Vacuum (timer), Gas flushing and Sealing.........................................................................................62
[1 time] Vacuum (gauge), Gas flushing and Sealing.......................................................................................64

[n times] Vacuum (manual), Gas flushing and Sealing....................................................................................66
[n times] Vacuum (timer), Gas flushing and Sealing........................................................................................69
[n times] Vacuum (gauge), Gas flushing and Sealing......................................................................................72
[Circulate] Vacuum (manual), Gas flushing and Sealing.................................................................................75
[Circulate] Vacuum (timer), Gas flushing and Sealing.....................................................................................78
[Circulate] Vacuum (gauge), Gas flushing and Sealing...................................................................................81
Replacing the routine maintenance parts....................................................... 84

9-1 Sliding teflon sheet............................................................................................................................... 85
9-2 Replacing teflon sheet.......................................................................................................................... 85
9-3 Replacing center-dry tape on the upper lever(object : double side heating model)............................. 86
9-4 Replacing heating element................................................................................................................... 87
9-5 Replacing glass tape(19mm width, 25mm width), sarcon sheet........................................................... 88
9-6 Replacing silicone rubber (object single side heating model).............................................................. 88
9-7 Replacing silicone rubber (object : double side heating model)........................................................... 89
9-8 Replacing 50mm width glass tape(object single side heating model)....................................................... 89
9-9 Connecting and removing tube............................................................................................................ 90
9-10 Replacing microswitch ...................................................................................................................... 90
9-11 Replacing nozzle................................................................................................................................ 91
9-12 Replacing temperature sensor for VG-602 series.............................................................................. 92
9-13 Replacing temperature sensor for VG-402 series.............................................................................. 93
10 Specification..................................................................................................... 94
10-1 Safety mechanism specifications....................................................................................................... 94
10-2 Safety mechanism specifications....................................................................................................... 94
10-3 Appearance dimensions drawing....................................................................................................... 95
10-4 Combination of vacuum pump and air compressor............................................................................ 96
10-5 Specifications by the combination of vacuum pump and air compressor........................................... 97
11 Specifications of accessories......................................................................... 98
11-1 Air parts.............................................................................................................................................. 98
11-2 Electric parts...................................................................................................................................... 98
12 Regular check and maintenance..................................................................... 99

12-1 Regular check.................................................................................................................................... 99
12-2 Cleaning the air filter........................................................................................................................ 100
13 Electric diagram.............................................................................................. 102

13-1 Electric diagram for 110V................................................................................................................. 102
13-2 Electric diagram for 220V................................................................................................................. 103
13-3 Electric diagram for 110V (without draining device)......................................................................... 104
13-4 Electric diagram for 220V (without draining device)......................................................................... 105
14 Piping diagram................................................................................................ 106

14-1 Piping diagram for VG-602/402 series with air compressor and vacuum pump............................... 106
14-2 Piping diagram for VG-602/402 series with air compressor and vacuum pump (Air is provided by the
outside compressor)................................................................................................................................... 107
14-3 Piping diagram for VG-602/402 series with air compressor and vacuum pump (with duct bracket).108
14-4 Piping diagram for VG-602/402 series with vacuum pump (Air is provided by the outside compressor)
(with duct bracket)...................................................................................................................................... 109
15 Common problems and solutions................................................................ 110

16 Exploded view of major parts........................................................................ 114
16-1 Sealing section.................................................................................................................................. 114
16-2 Inside of the frame cover.................................................................................................................. 114
16-3 Nozzle unit section........................................................................................................................... 115
16-4 Inside of the bottom plate................................................................................................................. 115
16-5 Inside of the body frame box............................................................................................................ 116
1 Package contents
Please check the following after opening the package:
Is the machine model the same as you have ordered?
Has any damage occurred during shipment? Are there any screws loose or any foreign objects mixed in machine?
Please to make sure that all of the accessories described below are included.
2 Foot switch-----------1
1 Machines body-----------1
for operation
3 Table-----------1
4 Accessories set
Hexagonal wrench (2.5 mm)
-----1
Double head wrench(10/13mm)

-----1
Heating element (heater)

The accessories set will vary with the machine type,
Glass tape (19mm width x 5m )

-----1
Phillips screwdriver
-----1
Filter element
-----2
Power outlet-----1
Vacuum pump oil

-----1
Please refer to the table on the below.
type
VG-602/402
VG-602/402-10D
5mm heater
10mm heater
5pcs.
5pcs.
10pcs.
110V
Low pressure gas hose (3meters)
-----1
Hose band(dia.14)
-----1
220V
Hose band(dia.12)
-----1
Only for AE,CE model

For VG-602/402-10D
Teflon center dry tape
(40mm width x 5m)-----1
Only for
CH,CD,CE,CG
model
These illustrations are not reduced equally.

5 Others
Certificate of inspection, Vacuum pump instruction manual, Air compressor instruction manual, Dry filer
instruction manual(except CH,CD,CE,CG) ----- one each.
If the items in package are not same with above list, please contract to our company or your local dealer.
Before using , to verify that the circuit breaker is in the "OFF" position. If not so, turn it to the "OFF"
before plug in.
2 Warning-Caution label location and content

Warning - Caution labels are placed in locations where there is a danger of injury to a person or damage to the
machine. Label location details are illustrated below. Please check them before beginning operation. Labels not
readily apparent are indicated by dotted lines.
Bottom
Inside construction
WARNING
Dont change the

position of the sensors,
otherwise the machine
may not work properly,
and danger
CAUTION
pinching
Frame cover
Inside of machine body

Body
CAUTION
pinching
On the upside of body frame
CAUTION
jamming
CAUTION
hot
If Warning - Caution labels peel off or are lost, please purchase the proper labels and place
them in the appropriate location.
Warning-Caution label location and content

Inside construction / top view
WARNING
electric shock
Frame cover and pressure lever
CAUTION
hot
CAUTION
pinching
Pay attention to the nozzle

moving forward or
backward during vacuum.
Pinching may occur.
CAUTION NOZZLE
When opening the cover for maintenance

checks, unplug the machine from the wall
outlet or an electric shock may occur.
Except
CH,CD,CE,CG
model
During packaging, do not place hand or

fingers in the sealing area.
Burns or pinching may occur.
Caution
This label indicates very important contents

on the maintenance of this sealer.
Ref. page 18
If Warning - Caution labels peel off or are lost, please purchase the proper labels and place
them in the appropriate location.
3 Operating precautions
3-1 For safety operating
Warning
In an emergency, unplug the power cord immediately.

This sealer incorporates a number of safety devices and is carefully
designed to prevent fires or other malfunctions. However, should all of the

safety devices fail simultaneously, there is a possibility of the teflon
catching fire due to a failure of the heating circuit's tripping mechanism
that results in the heating element overheating. Should smoke or fire appear
from the teflon, immediately turn OFF the power or unplug the power cord
from the outlet.
Warning
The power consumption varies according to the machine

type. Check that the capacity of the outlet is larger than the
power consumption of the sealer, and plug it firmly into the
outlet.
110V
specification
Use of an outlet with a smaller capacity or an extension cord causes a drop

in voltage, resulting in malfunction or even fire, be sure to use an
appropriate outlet.
220V
specification
Warning
Do not use for packaging liquids since machine is not

waterproof.
Do not splash water on the machine or use machine for packaging liquids.
There is a danger of electrocution or malfunction of the machine.
Warning
Do not insert any metal objects into the sealing section

Please do not place any metal objects into the sealing section during
operation. This could cause electrocution.
Warning
When replacing routine parts, unplug the power plug

Routine maintenance parts will wear as you use your sealer. Perform
periodical checks of them and set-up an appropriate maintenance
schedule. Parts should be replaced in accordance with "Parts
Replacement" on the page of instruction manual and perform the steps

correctly. Before replacing parts, unplug the machine from the power
source otherwise, it may cause electrocution.
110V
specification
220V
specification
10
Warning
Do not modify the machine

Please do not tamper with the machine without the guidance or permission
of our engineers. Accidents or damage caused by modification by the
customer is the sole responsibility of the customer.
Warning
Do not try to use the sealer if the circuit breaker

automatically turns to the OFF position.
Trying to use the sealer when the circuit breaker automatically turns to the
OFF position may cause electrocution. Do not operate the machine until
the cause of the shut down is ascertained and the problem has been
addressed.
Be careful of nozzle motion

Nozzle comes out automatically after several seconds from the finish of
Caution
operation at the mode except "SEALING ONLY".

Please be careful of advance of a nozzle.
If you bring face or hand close to the sealing area, you might bump against
a nozzle.
Or if a bag is left in the front of a seal part, the goods in the bag might be
damaged.
Please take out a bag soon after pressure lever open (Sealing is finished).
Caution
Do not operate machine under high humidity; Do not expose

the machine to water vapor; and do not use it for powder
applications or in a dusty location.
To operating the machine in a place with high humidity or water vapor, The
machinery parts will become rusty; Electric insulation reduces.
Electrocution and malfunction may occur.
To operate the machine for powder packaging or use it in a dusty location,
The powder and dusty may flow inside the sealer body, Electric insulation
reduces. Electrocution and malfunction may occur.
Do not place hands in the sealing section.

With prolonged use, the sealing section will retain heat and become hot. If
Caution
you place your fingers in this area, there is a possibility of burns.

Pressing the foot switch applies press to the sealing section. Take sufficient
care so that your fingers are not caught while the power is on.
An operation by two operators may increase the possibility of your fingers
being caught. Take sufficient.
11
Caution
Read the operating instructions carefully and operates

sealer correctly.
Accidents or damages caused by misuse of the machine not in accordance

with the operating instructions are the sole responsibility of the customer.
Caution
Perform sufficient tests headband when you require a

particularly strong vacuum seat.
Sealing results vary according to heating, cooling, and pressure. A certain

type of film may greatly affect the necessary sealing settings. Perform a
number of sealing tests to find the most suitable heating cooling time and
pressure setting for your film before start sealing operation.
Socket for the optional printer (FEP-V-N1)

There is a socket to install the optional printer (FEP-V-N1) on the top of a
sealer.
Caution
Don't connect the other electrical appliances to this socket.

To start it is very dangerous.
12
3-2 For smooth operation

Heating time should be set at a minimum
Set sealer so that an acceptable seal is completed in the least amount of
heating time. Excessively long heating times (increasing the heat setting
unnecessarily) will damage the Teflon, glass tape and other consumables,
as well as result in heating element breakage. This will lead to decreased
work productivity and unnecessary power consumption.
Allow sufficient cooling time

Cooling temperature is important when using an impulse sealer. After the
film is heated, the film must be cooled with the frame and pressure lever in
the closed position. If cooling temperature is extremely lower, the working
efficiency will come down. So please set the appropriate cooling
temperature according with the film.
When abnormalities arise in a temperature sensor

Since the temperature sensor detected the temperature of a heater portion
directly and has controlled it, if the tip part of a temperature sensor
separates from a heater, an error message "Poor heating" will be displayed
on a screen and a lever will return to the initial state.
Please be careful to set the temperature sensor exactly after the replacement
of parts in the sealing area.
When the teflon, silicone rubber becomes damaged

The teflon, silicone rubber will start to wear with use. Once they are
damaged, it will be difficult to achieve smooth and strong seals.
Thoroughly read how to replace the parts and be careful when doing so.
Dust in the sealing section

Dust will prevent attainment of a smooth seal. It could also cause damage
to heating element and/or other routine maintenance parts. Before using the
machine, clean the sealing section.
3-3 Other safeguards

Fuji Impulse sealers utilize an impulse heating system, meaning that the
heater section does not become hot simply because the power has been
turned on.
It is programmed so that the heating element is heated only during the
heating cycle, after a sensor switch and micro processor have been
activated. (Please note, however, the sealing section may become hot after
prolonged operation.)
13
4 Outline of structure
VG-602/402 series is an impulse sealer with sponges
located on the sealing section to secure the nozzle prior
to air removal. The air in a pouch is exhausted by built-
1
Bag
in vacuum pump, and after the gas flushing process,

sealing starts.
Sponges
Sealing section
Table
Nozzle forward
Built-in air compressor (another air source for some

models) moves each part.
Vacuum
Vacuum
The operation process is controlled by control unit and

performed just simply by depressing the foot switch.
Gas flushing
Gas
Sealing
Press
Nozzle backward
Finish
Pressure lever raise up
Nozzle forward
5 Purpose usage of the sealer

1 The impulse sealer is a machine that sends strong electric current quickly to the thin ribbon heater, which
presses against the film and instantly heat-seals the package. Though this machine yields superior quality
sealing, it is not compatible with films thicker than that indicated in the diagram below, sponge-like sheets,
and materials that are not able to withstand high heat. In addition according to difference of film thickness
and martial, the heating temperature is different. Please verify the optimum sealing conditions before
operation.
2 Film thickness limits for VG-602/402 series are described below. The machine can't seal films that are
thicker than that indicated.
The machine may malfunction if you try to exceed the limits of the machine.
Heating type
14
Heater width Thickness of material (combined total of two sheets)
Single side heating(VG-602 / 402)
5mm
Single side heating(VG-602 / 402)
10mm
Thin gusset film with thickness of 0.4 mm or less

Laminated film with thickness of 0.4 mm or less
Double side heating(VG-602 / 402-10D)
10mm
Thin gusset film with thickness of 0.5 mm or less

Laminated film with thickness of 0.5 mm or less
Single layer film with thickness of 0.3 mm, or less or thin laminated film
6 Major parts and function

Control (switch) panel
Dry filter
To prevent any condensation

inside the compressor from
sealer body. The moisture is
discharged from the dry hose.
Frame cover
Can be opened for maintenance
Circuit breaker (with overheat

proof circuit)
Vacuum / Gas-flushing nozzle
Any extreme heating time more than the

setting will be automatically stop--"OFF".
In addition, if electric leakage occur, it
automatic turns off.
Circuit breaker is behead
of the dry filter, it's no
available on this
drawing, please refer to
"appearance dimension"
on page 52.
This machine is equipped with a

nozzle so that a seal can be formed
at the top of the bag, and the spacing
between the nozzles can be adjusted.
Air filter
Store any foreign objects

accidentally taken in though
the nozzle in air filter cup.
Table
Angle of the table can be adjusted.
Emergency stop switch

Cock
Two type gas can be used.
Angle adjusting handle
Turn the handle to change the angle

of sealing area.
Automatic water draining device

When the water draining switch is
turned ON, all water, dust, and foreign
object will be emptied out.
Foot switch
Press the foot switch to perform the operation.
Control (switch) panel

9
6
3
10
11
12
13
1. POWER BUTTON
9. VACUUM GAUGE
2. ENT BUTTON
10. VACUUMING LAMP
3. MENU BUTTON
11. GAS LAMP
4 5 6 7. ARROW BUTTON
12. HEATING LAMP
8. LIQUID CRYSTAL DISPLAY
13. COOLING LAMP
15
7 Preparation
7-1 Securing the work place
For safety and efficiently operation, please set the sealer
in suitable environment.
Warning
Do not use the VG-602/402 on a tilting,

uneven, or unstable place. The sealer may
fall and become damaged or cause injuries.
Be sure it uses the sealer on a flat stable
surface.
Warning
Do not use the sealer on a wet floor. Do not

expose the sealer to water drops or vapor.
This may cause a failure and a short circuit.
Warning
To operating the machine in a place with

high humidity or water vapor, the
compressor draw the air obtain more
moisture, It's worse to machinery parts. Life
of dry filter will be shorten.
7-2 Connect the power source

Be sure to connect the power plug directly into an outlet
with an appropriate capacity, which stated on "10
Specification".
Insert the plug fully into the outlet.
110V specification
Wiring must be performed by an engineer authorized by

the electric, power company.
(Wiring and 3rd level grounding requires proper
qualification.)
220V specification
16
Warning
The power consumption varies according to

the machine type. Check that the capacity
of the outlet is larger than the power
consumption of your machine, and plug it
directly to the outlet.
Using an outlet with a smaller capacity or
an extension cord will cause a drop in
voltage, resulting in malfunction and even
fire because of overheating of the cable and
outlet. Be sure to use an appropriate outlet.
Warning
When you have changed the standard plug

provided, check the connection.
The wires are connected as shown in the
figure. When the ground wire is not
connected to the correct terminal, a short
on the power source side or an electric
leakage is caused.
110V specification
Black
220V specification
Black
White
White
Ground
Green
Ground
Green
7-3 Installing the foot switch

Insert the foot switch that comes with into the plug in
the right side machine body.
Turn and push the collar to lock it in place.
Collar
7-4 Adjusting the height and angle of the table

The height and angle of the table can be adjusted
through the rod holes located on the front both ends of
machine.
Height
Attaching / Taking off the table

To attach the table, hold the table on both ends, push
the buttons in and push the table into the rod.
To take off the table, do the opposite.
While pushing the buttons on both ends, pull the table
towards you.
The table will come off the rod.
Angle
Push button
Rod (upper)
Attaching / Taking off the legs

This works best if it is done one side at a time.
To attach the legs, select a hole so that the table is at
an appropriate angle and place the hooks in the holes,
with pushing the legs inside as the illustration.
Be careful so that legs are the same angle.
To take the legs out, lift the table slightly and take the
hooks out of the holes.
Caution
Make sure the hooks are securely in the

holes so that the table is stable.
If the table is unstable, a little shock or
movement of the table can cause the table
to fall off or slant, causing injuries.
Table legs
Bolt
Rod (lower)
17
7-5 Check the dry filter

Two dry filters on the side of frames need to be
exchanged regularly.
Especially check the red filter side tube when the
beginning and finishing the sealing operation.

When the tube becomes cloudy or water-drops is
attached inside, please exchange the filter regardless of
the standard of exchange.
Standard of exchange
Black filter-----2 years
Red filter----- Half a year
7-6 Cleaning by the weeping valve

(Not necessary at the initial use of the sealer)
At the beginning and finishing the sealing operation,
clean the filter interior by pushing the weeping valve in
Weeping valve
Check the red filter

side tube
Black
Red
Dry filter
and out several times.

For details information, refer to " dry filter instruction
manual".
Caution
If the filter would be left clogging up, the

moisture flow into the vacuum pump and
causes damage of pump.
Taking water by a
container
7-7 Taking water by the drain hose

The dry filter is of auto-drain construction.
The moisture in the dry filter is mixed with little exhaust
air and discharged as drain.
It will be released from the underside of the unit frame
by the drain hose.
Take water from the drain hose by a container (drain
tank or empty can).
7-8 Adjusting the nozzle position

Take off the frame cover.
Adjusting the height of the nozzle
Turn the screw on the inner left of the nozzle
supporter (seen from the table side) by the 2.5mm six
angle wrench.
To lower = Turn clockwise
To raise = Turn counterclockwise
18
Rear side
silver screw
Adjusting the spacing between two nozzles

Nozzles can be moved to a comfortable working
position, according to the width of your bag.
How to adjust
Nozzle supporter
Black screw
1 Loosen the black screw on the nozzle supporter

with the allen wrench (2.5mm).
2 Slide the nozzle supporter and make the
appropriate adjustments depending on the width of
the bag that you are using.
(Nozzle spacing is max. 157mm, min 57mm)
Secure the black screw.
3 Confirm the spacing is correct and close the frame

cover.
7-9 Adjusting the angle of sealing area

The angle of sealing area can be adjusted from 0 to
30 degrees.
How to adjust
Turn the black handle located on the front of
machine.
Angle of sealing area can be selected freely.
Angle adjusting handle
Turn clockwise = to 0 degree

Turn counter-clockwise = to 30 degrees
19
Circuit breaker
ON
7-10 Emergency stop switch

Before operating the machine, press the switch and
make sure that it is working.
1 Turn the circuit breaker ON.
2 Press the emergency stop switch.

3 If the circuit breaker turned OFF, the emergency
stop switch is working normally.
Press the emergency

stop switch
Warning
If the circuit breaker does not shut down, please try

as follows and contact your dealer of our company.
(Ref. the right illustration)
Push the red test button on the circuit breaker.

<Circuit breaker turns OFF>
=Emergency stop switch may be damaged.
OFF
ON
<Circuit breaker turns ON>

=Circuit breaker may be damaged.
7-11 Attaching the gas tank and gas adjuster

Gas tank and adjuster is not attached to the machine.
Please attach as necessary.
1 Attach the gas adjuster (with reducing valve and
flow meter) to the tank.
2 Attach the gas flow meter to the cock with vinyl

hose.
When using only one cock, close the other cock
certainly. (Both cocks can be connected.)
If two types gas are used, attach the another hose
to the each cock.

When gas flushing process is not necessary, always
close the gas cock.
20
Cock
Test button
(Red)
8 Proper use of the sealer

This chapter is composed as follows.
8-1 Operation by the initial set up
= Standard operation
Please get used to this sealer by initial two patterns.
8-2 Entry
Let's enter the new operation pattern.
T I PS
Explanations in 8-1 and 8-2 are started after the following operations (1 and 2).
1 Turn the circuit breaker on.
2 Turn the power switch on.
The below message is displayed for 3 seconds.

VG English Verx.x
VG English Verx.x
FUJI IMPULSE.CO
FUJI IMPULSE.CO
8-3 Explanation of the terms

Explanation about the display message or term in this manual.
Please use as dictionary.
8-4 Reference
Explanation of each operations and set-up.
8-5 Operation procedure
Work flow of 13 patterns combination of sealing method.
Please use 8-3 and 8-4 as your dictionary (data file)
21
8-1 Operation by the initial set up = Standard operation

Four kinds of sealing methods are entered into VG-602/402 series at the shipment from factory.
Attention
The following four patterns will be changed when customer set up heating temperature, cooling temperature,
vacuum time, gas flushing time etc...
If you need the initial patterns, please re-register it.
*At first, get used to the machine by these four patterns.

*Terms are explained in page 31, 8-3.
*Other sealing methods are shown in page 50, 8-5.
Seal only (page 21)
= Operation No. [01] SEALING ONLY
Initial value
HT (Heating Temperature) : 284 F (140 C), CT (Cooling Temperature) : 212 F (100 C)
Ref. 8-5-1 (page 50)
O
Vacuum and seal - Operator decide the finish of vacuum by seeing (page 22)
= Operation No. [02] VAC & SEAL manual
Initial value
Ref. 8-5-2 (page 52)
O
Gas flushing and seal - by initial set up vacuum and gas flushing time (page 24)
= Operation No. [03] 1-GAS / Timer
Initial value
VT (Vacuuming Time) : 1.0second, GT (Gas flushing Time) : 2.0seconds
Ref. 8-5-6 (page 60)
O
Two times gas flushing and seal - by initial vaccum and gas flushing time (page 26)
= Operation No. [04] 2-GAS / Timer
Initial value
1-VT (1st Vacuuming Time) : 1.0second, 2-VT (2nd Vacuuming Time) : 1.0seconds,
O
1- GT (1st Gas flushing Time) : 2.0seconds, 2-GT (2nd Gas flushing Time) : 2.0seconds
Ref. 8-5-6 (page 60)
Operation No. can be changed by
key on the following display.
SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
22
Sealing only
Operation No. [01] SEALING

HT : 284 F (140 C), CT : 212 F (100 C)
Ref. 8-5-1
O
T I PS
The following explanation is for the first use. (by
the initial set-up)
At first, turn the circuit breaker and power

switch on. (in page 19, 1 and 2)
3 Operation No. [01] is displayed.
SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
4 Check the heating and cooling temperature.

When you change the value, please look at 8-4
in page 32.
5 Set a pouch on the sealing position.
7 Step on the foot switch (2nd)

By the second step on the foot switch, the
following process (from 7-1 to 7-5) will be
performed automatically.
7-1 Sealing starts.
7-2 Heating lamp is turned on.
7-3 After the heating is finished (Heating

lamp is turned off), cooling lamp is turned on.
7-4 Cooling is finished.

(Cooling lamp is turned off.)
7-5 Sealing process is completed.

(Pressure lever open.)
8 Sealing is finished.
Please check whether sealing performed
certainly.
6 Step on the foot switch (1st)
If you will not use for a long time, please

work in following order.
1. Shut off the power switch.
2. Shut off the circuit breaker.
3. Pull out the cord from the wall socket.
Pressure lever descends and fasten a pouch

with sponge rubber. (Please keep on stepping
until the pressure lever close.)
Attention
If leg is separated from the foot switch in the

middle of downward, the pressure lever will
open for the safe mechanism.
23
Vacuum and seal - Operator decide the finish of vacuum by seeing

Operation No. [02] VAC & SEAL
HT : 284 F (140 C), CT : 212 F (100 C)
Ref. 8-5-2
O
T I PS
the initial set-up)
7 Insert the nozzle in a pouch, and set it on

the sealing position.

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
4 Select No. [02]

Operation number is changed by
button.
Select number [02].
VAC&SEAL manual
Change(number)
Change(item)
COUNTER
xxxxx

in page 32.
Nozzle come forward.

Attention

9 Step on the foot switch (3rd)

Vacuum start. (Vacuum lamp is turned on.)
10 When you could see the sufficient vacuum

is done, step on the foot switch (4th).
By fourth step on the foot switch, the
following process (from 10-1 to 10-6) will
be performed automatically.
10-1 Vacuum finish.

(Vacuum lamp is turned off.)
10-2 Nozzle return.
24
(8-1-2)
10-3 Pressure lever fasten a pouch and
sealing starts. (Heating lamp is turned on.)



(Pressure lever return and nozzle come
forward)
certainly.
25
Gas flushing and seal - by initial set up vacuum and gas flushing time
Operation No. [03] 1-GAS / Timer
HT : 284 F (140 C), CT : 212 F (100 C), VT : 1.0sec, GT : 2.0sec
Ref. 8-5-6
O
T I PS
the initial set-up)


SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
4 Select No. [03]

button.
Select number [03].
1-GAS timer
Change(number)
Change(item)
COUNTER
xxxxx

in page 32.

Attention


By third step on the foot switch, the
9-1 Vacuum start. (Vacuuming lamp is turned

on.)
9-2 When set up time is passed, vacuum

finish. (Vacuuming lamp is turned off.)
9-3 Gas flushing start.
(Gas flushing lamp is turned on.)
26
(8-1-3)
9-4 When set up time is passed, gas flushing
finish. (Gas flushing lamp is turned off.)
9-5 Nozzle return.
9-6 Pressure lever fasten a pouch and sealing
starts. (Heating lamp is turned on.)


forward)
certainly.
27
Two times gas flushing and seal - by initial set up vacuum and gas
flushing time
Operation No. [04] 2-GAS / Timer
HT : 284 F (140 C), CT : 212 F (100 C), 1-VT : 1.0sec, 2-VT : 1.0sec, 1-GT : 2.0sec, 2-GT : 2.0sec
Ref. 8-5-9
O
T I PS
the initial set-up)


SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
4 Select No. [04]

button.
Select number [04].
1-GAS timer
Change(number)
Change(item)
COUNTER
xxxxx

in page 32.

Attention


By third step on the foot switch, the
9-1 Vacuum start (1st).

(Vacuuming lamp is turned on.)
9-2 When set up time is passed, the first

vacuum finish.
(Vacuuming lamp is turned off.)
9-3 Gas flushing start (1st).

28
(8-1-4)
9-4 When set up time is passed, the first gas
flushing finish.
(Gas flushing lamp is turned off.)
9-5 Vacuum start (2nd).
(Vacuuming lamp is turned on.)
9-6 When set up time is passed, the second

vacuum finish.
(Vacuuming lamp is turned off.)
9-7 Gas flushing start (2nd).
9-8 When set up time is passed, the second
gas flushing finish.
(Gas flushing lamp is turned off.)
9-9 Nozzle return.
9-10 Pressure lever fasten a pouch and
sealing starts. (Heating lamp is turned on.)


forward)
certainly.

29
8-2 Entry
Attention
Maximum ten operation numbers can be entered in this machine.

If the eleventh operation pattern is going to be entered, "Entry No' is full Please delete an
unnecessary entry No' " message is displayed on a liquid crystal screen.
You cannot input the new pattern unless either of already entered operation number would be
deleted.
Attention
The biggest number is automatically assigned to the new entry.

*If there are 4 operation numbers, the new entry becomes 05.
Two kinds of examples for the new entry are explained in 8-2.
Please get used to enter and try on another sealing pattern.
Entry for sealing only (page 29)
Operation No. [05] SEALING ONLY
Setting value : Heating temperature 284 F (140 C), Heating time 0.3seconds
Cooling temperature 212 F (100 C)
O
Entry for 1 time vacuum and gas flushing by timer (page 30)
Operation No. [06] 1-Gas / Timer
Setting value : Heating temperature 284 F (140 C), Heating time 0.3seconds
Cooling temperature 212 F (100 C), Vacuum time 12.0seconds, Gas flushing time 8.0seconds
O
30
Entry for sealing only

Attention
The following explanation is for the first use. (by the initial set-up)
To register "Sealing only" in operation number [05].

Setting value : Heating temperature 284 F (140 C), Heating time 0.3seconds, Cooling temperature 212 F (100 C)
O

, display changes to
8 Push
Change
Move

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
4 Push the
part is blinking.)
Change
(
/ MENU=Back
2 Change
4 Circulate
6 Maintain
MENU /
1 Entry
3 Delete
5 Drain
5 Select "1 Entry" Register by
part is blinking.)
.
Look at "Set the heating time "in page 34.
11 Set the cooling temperature 212 F
O
METHOD
Select
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
10 Set the heating time to 0.3seconds by
(100 C) by
6 Push
part is blinking.)
9 Set the heating temperature 284 F (140 C).

Look at "Set the heating temperature" in
page 34.
/ ENT=OK
2 Change
4 Circulate
6 Maintain
MENU /
1 Entry
3 Delete
5 Drain
Move
Look at "Set the cooling temperature" in

page 43.
(5 CIRCULATE is displayed only in effect)
7 Select "1 SEAL" by
METHOD
Select
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
(
part is blinking.)
31
Entry for 1 time vacuum and gas flushing by timer

Attention
The following explanation is for the first use. (by the initial set-up)
To register "1 time vaccum and gas flushing by timer" in operation number [05].
Setting value : Heating temperature 284 F (140 C), Heating time 0.3seconds, Cooling temperature 212 F (100 C)
Vacuum timer 12.0seconds, Gas flushing time 8.0seconds
O

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
1 Manual
5 Select "1 Entry" Register by
part is blinking.)
METHOD
Select
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
7 Select "3 1-GAS" by
METHOD
Select
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
(
part is blinking.)
8 Push
VAC TYPE
1-GAS
1 Manual
(
32
2 Time
6 Push
Select
part is blinking.)
Change
Move
1VT10.0sec G10.0sec

part is blinking.)
11 Set the vacuum timer to 12.0seconds.

Look at "Set the vacuum time" in page 41.
12 Push
, and set the gas flushing timer
to 8.0seconds.
Look at "Set the 1 time gas flushing
timer"in page 45.
13 Push
, and set the heating
temperature 280 F (140 C).

O
part is blinking.)
Look at "Set the heating temperature" in

page 34.
14 Push
, and set the heating time to
0.3seconds.
Look at "Set the heating time "in page 34.

15 Push
, and set the cooling
temperature 212 F (100 C).

Look at "Set the cooling temperature" in
page 43.
O
3 Gauge
3 Gauge
Change
Move
1VT10.0sec G10.0sec
/ ENT=OK
2 Change
4 Circulate
6 Maintain
MENU /
1 Entry
3 Delete
5 Drain
part is blinking.)
10 Push
Select
2 Time
/ MENU=Back
2 Change
4 Circulate
6 Maintain
MENU /
1 Entry
3 Delete
5 Drain
9 Select "2 Time" by

VAC TYPE
1-GAS
4 Push the
8-3 Explanation of the terms

Impulse sealer
The machine which carries out the seal of plastic film package is
named sealer. The sealer which carries out the seal by heat is
called heat sealer.

There are four heat sealing technology generally used.
1 Impulse sealer, 2 Heat plate sealer
3 Ultrasonic sealer,
4 High frequency sealer
Impulse sealer passes large current momentarily at the ribbon-like

heating element, and heat up it to the sufficient temperature to
seal by heat conduction.

Package material is put between sealing parts of machine, pressed
by the lever and melted by the heating element. After that, cooling
process is needed with pressure kept on.
Temperature sensor
It can detect the temperature of sealing part directly.
Vacuum (gauge)
Vacuum is performed to the set-up degree by vacuum gauge.
Seal
Seal (Sealing) means to adhere the opening part of plastic film
Sealing only
Only seal is performed. If this pattern is set-up, vacuum or gas

flushing function will not work.
Sealing method
(on the liquid crystal screen)
"METHOD" appears on the liquid crystal screen of VG-602/402

series when operator select the sealing method.
(Sealing only / Vacuum and Seal / Vacuum, Gas flushing and seal)
Sealing
package material.
The machine which perform "Seal" is called sealer.
Sealing method generally means "Impulse style", "Ultrasonic

style", "High frequency style" etc...
Please understand it as the shortage of expression.
Vacuum (timer)
Vacuum is performed to the setting time by timer.
Vacuum (manual)
Operator judges the suitable vacuum degree by seeing, and finish
n-times
(Gas flushing)
(Vacuum)
In VG-602 / 402 series, gas flushing can be set max.99 times.

"n" expresses the unspecified number of times which user would
choose from 1 time to 99 times.
NC(piping)
Circulated vacuum and gas flushing mode is called "NC".

When user choose this mode,piping needs to be changed. Piping
the vacuum by stepping on a foot switch.
for circjlated vacuum and gas flushing mode is "NC piping".

Gas nozzle
Vacuum nozzle
Gas nozzle
Vacuum nozzle
Gas nozzle Vacuum nozzle Gas nozzle
Vacuum nozzle
Nozzle comes
forward
Vacuum
(by manual, timer, or
gauge)
First gas flushing
Circulation
Gas flushing and
vacuum are performed
simultaneously
Second gas flushing
Nozzle returns.
Heating starts.
33
8-4 Reference
For operation
Starting of use
1 Turn on the circuit breaker.
2 Push the power button (ON).

Compressor and cooling fan start.
Foot switch
In VG-602/402 series, sealing process is
done by the foot switch.
Attention
Please step on the foot switch certainly.

If not, machine may not work to the next
process.
Finishing of use
1 Push the power button (OFF).
Compressor and cooling fan stop.
2 Shut off the circuit breaker.

All function is finished.
3 Check the maintenance items.

Ex. Cleaning of Filter element.
Look at page 97 for periodical
maintenance items.
4 Pull out the plug.

If machine won't be worked for a long
time, pull out the plug from the wall
socket.
34
For set-up
Explanation of each button on the control panel
MENU button
= To display the menu mode
1 Entry
2 Change
3 Delete
4 Circulate
5 Drain
6 Maintain
ENT button
= To decide the each setting item
Arrow button / Upward, Downward

Liquid crystal screen
Please refer 8-5
= To move the setting display

= To increase or decrease the setting value
Arrow button / Rightward, Leftward
= To move the setting display
= To move the cursor to objective position
35
Foreword
1 The following explains as the circuit breaker ON and power button ON.
2 The numeric position which can be changed is expressed by xx in the illustration.
3 The blinking cursor position is expressed by (down side) and (background).
shows different contents by each operation number.
4
Counter
Reset the counter value :
for 3 seconds on the following initial
Push
display.
SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
One degree is changed by one time push
one time.
T I PS
Suitable temperature is different with each
packing materials.
Please set the lowest temperature which can
seal. Seal speed will increase and useless
consumption of parts can be lost.
Set the heating temperature

1-1 Change the heating temperature of the
current displayed operation number :
Push
In this condition, adjust the value by

button.
.
If kept on pushing, numeral change at high speed.
(Setting range 140 480 F)
(Setting range 60 250 C)
Reduce one count from the counter value :

Push
2 Right side of "HT" is blinking.
Change
Move
Set the heating time

1-1 Change the heating time of the current
displayed operation number :
Push
part is blinking.)
display changes to
Change
Change
Move
Move

part is blinking.)
part is blinking.)
->Read 2
Change
1-2 Change the heating temperature of

another operation number :
Refer to "Select the operation number" in page
36.
After select the objective number, push

read 2.
and
Move
part is blinking.)
->Read 2
1-2 Change the heating time of the another
operation number :
36.
After select the objective number, push
read 2.
36
and
Delete the operation number
T I PS
Push
and cursor move to the heating time
position [x.xs].
,
.
Adjust the time by
,
0.1second is changed by one time push
If kept on pushing, numeral change at high
Deletion can be stopped by pushing

has not been pushed.
button, if step 4-
1 When screen displays operation No.

(ex. [01] SEALING ONLY)
speed.
(Setting range 0.0 2.0second)
T I PS
In temperature control system, heating time
means the time which maintains the set-up
temperature.
Usually seal can be made even if heating time
doesn't set (0.0sec).
In the case that thickness of packing material
causes the poor sealing, or the film is received
the damage, setting of heating time might be
effective.
SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push
and display changes to

MENU /
1 Entry
3 Delete
5 Drain
2 Put the cursor to 3 Delete by
push
In the case that heating time is not set up.

Set-up heating
temperature
Heat cycle
/ MENU=Back
2 Change
4 Circulate
6 Maintain
to decide. Display changes to
and
Select(number)
ENT / Delete
Cool cycle
Set-up cooling
temperature
In the case that heating time is set up.

Set-up heating
temperature
Cool cycle
Set-up cooling
temperature
Heat cycle
Heating time
3 Select the operation number to delete by

.
4 Push
number.
button to delete the selected
T I PS
As once deleted number cannot be returned,
please be careful at the deletion.
T I PS
When the operation number is deleted, the
next number is automatically moved one
forward.
(Sample)
Before
No.1 = SEALING ONLY
No.2 = VAC&SEAL timer
No.3 = 1-GAS manual
After deleting No.1, Display changes to
No.1 = VAC&SEAL timer
No.2 = 1-GAS manual
No.3 = Not registered
37
T I PS
If the registered number is only [01], you
cannot delete it.
When you try to delete a message "You can
not delete all" is displayed.
Select / Enter / Change the sealing method

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push
Select the operation number

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push
or
button.

MENU /
1 Entry
3 Delete
5 Drain
/ MENU=Back
2 Change
4 Circulate
6 Maintain
2-1 Entry : Put the cursor to "1 Entry" by

and push
The next operation is 3.
2-2 Change of contents : Put the cursor to "2
,
and push
Change" by
Display changes to the for selecting the
operation number. Then select the number by
,
and push
.
3 Display changes to
METHOD
ENT=OK
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
4 Put the cursor on 1 SEALING ONLY, 2

VAC&SEAL, 3 1-GAS, 4 n-GAS or 5
,
and push
CIRCULATE, by
Then display changes to the one for setting
heating temperature, time and cooling
temperature.
T I PS
When select 2~4 (except), please refer to
"Select the vacuum pattern" in page 42.
38
Select the gas circulation

Process 1-3 is necessary only at the first set of
gas circulation, or in the state of circulation /
off.
1 Open the flame cover.
7 Then display changes to the one for

selecting the vacuum method.
Select to one from 3 pattern :
1 Manual, 2 Time,3 Gauge.
VAC TYPE
CIRCULATE
2 Turn the circulation switching knob to the

vertical position as following illustration.
1 Manual
2 Time
Select
3 Gauge
8 About the next setting, please refer to the

following page
1 Manual : page 38
2 Time : page 39
3 Gauge : page 40
3 Close the frame cover to the initial position.

4 When the operation number is displayed,
SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push the
button, display changes to
MENU /
1 Entry
3 Delete
5 Drain
/ MENU=Back
2 Change
4 Circulate
6 Maintain
5 Put the cursor to "4 Circulate" by

.
and push
6 Display changes to the one for selecting the

gas circulation.
Put the cursor to "2 ON" by
and push
CIRCULATE
Select
ENT=Go
1 OFF
2 ON
(Brinking number (
) is selected now.)
(At the first set of gas circulation, cursor is

under the "1 OFF")
39
Set the gas circulation / vacuum by manual

1 Refer "Select the gas circulation" (page 37).
After the process of 6, put the cursor to "1
and push
Manual" by
VAC TYPE
CIRCULATE
1 Manual
2 Time
4 Set the second gas flushing time.

Put the cursor to "Gxx.xsec" by
and set the
,
.
time by
(Setting range : 0.1 99.9seconds)
Select
Change
Move
3 Gauge
part is blinking.)
2 Display change to
Change
Move
Change
Move
part is blinking.)
Change
Move
part is blinking.)
Cursor is under the position for setting the first

gas flushing time.
,
.
Adjust the value by
3 Then set the gas circulating time.

Put the cursor to "GCT xx.xsec" by
,
.
set the time by
Change
Move
part is blinking.)
Change
Move
40
part is blinking.)
, and
part is blinking.)
Set the gas circulation / vacuum by timer

After the process of 6, put the cursor to "2
Time" by
and push
VAC TYPE
CIRCULATE
1 Manual
2 Time

Put the cursor to "GCTxx.xsec" by
,
.
the time by
and set
Select
3 Gauge
Change
Move
part is blinking.)
Change
Move
part is blinking.)
Change
Move
part is blinking.)
Cursor is under the position for setting the

vacuum time.
"1 VT" = 1st Vacuum Time
,
.
Adjust the value by
3 Then set the first gas flushing time.

and set the
,
.
time by
Change
Move
part is blinking.)

and set the
,
.
time by
Change
Move
part is blinking.)
Change
Move
part is blinking.)
Change
Move
part is blinking.)
Change
Move
part is blinking.)
41
Set the gas circulation / vacuum by gauge

After the process of 6, put the cursor to "3 Gauge"
.
by and push
VAC TYPE
CIRCULATE
1 Manual
2 Time

Put the cursor to "GCTxx.0sec" by
,
.
the time by
(Setting range : -1 -100kpa)
and set
Select
3 Gauge
Change
Move
VG - kpa
Change
Move
VG - kpa
part is blinking.)
Change
Move
VG - kpa
part is blinking.)
(
Change
Move
VG - kpa
part is blinking.)
Cursor is under the position for setting the

vacuum degree.
"1VG" = 1st Vacuum Gauge
,
.
Adjust the value by
part is blinking.)

and set the
,
.
time by
Change
Move
VG - kpa
part is blinking.)
3 Then set the first gas flushing time.

and set the
,
.
time by
Change
Move
VG - kpa
part is blinking.)
Change
Move
VG - kpa
42
part is blinking.)
Change
Move
VG - kpa
part is blinking.)
Reset the gas circulation

1 Open the flame cover.
2 Turn the circulation switching knob to the
horizontal position as following illustration.
Set the vacuum degree

Refer to "Select the vacuum pattern" in page
42. Select "2 VAC&SEAL". Put the cursor to
"3 Gauge" and push
Change
1VG - kpa
. Display changes to
Move
part is blinking.)
Change
1VG - kpa
3 Close the frame cover to the initial position.

4 When the operation number is displayed,
part is blinking.)
Cursor is under the position of vacuum degree.
SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push the
Move
,
.
Adjust the value by
button, display changes to
MENU /
1 Entry
3 Delete
5 Drain
Set the vacuum time

Refer to "Select the vacuum pattern" in page
42, and select "VAC&SEAL".
/ MENU=Back
2 Change
4 Circulate
6 Maintain
5 Put the cursor to "4 Circulate" by

.
and push
Display change to
Put the cursor to "2 Time" and push

Display changes to
,
Change
1VT sec
Move
CIRCULATE
Select
ENT=Go
1 OFF
2 ON
(Brinking number (
part is blinking.)
Change
1VT sec
) is selected now.)
Move
6 Display changes to the one for selecting the

gas circulation.
Put the cursor to "1 OFF" by
and push
part is blinking.)
Adjust the value by

,
.
CIRCULATE
Select
ENT=Go
1 OFF
2 ON
(Brinking number (
) is selected now.)
43
Select the vacuum pattern

Set the drain ON / OFF

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push
SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push
/ MENU=Back
2 Change
4 Circulate
6 Maintain
MENU /
1 Entry
3 Delete
5 Drain

MENU /
1 Entry
3 Delete
5 Drain
2-1 Entry : Put the cursor to "1 Entry" by

and push
.
2 Put the cursor to "5 Drain" by and push

to decide.
DRAIN
2-2 Change the contents : Put the cursor to "2

,
Change" by
and push
3 Display changes by
to decide.
1 Manual
2 Time
Select
3 Gauge
Select the one from 1Manual, 2 Time, 3 Gauge

by
and decide by
Then display changes to the one for setting the

heating temperature, time, and cooling
temperature. Please set them at the suitable
value.
44
) is selected now.)
3 Put the cursor to 1 OFF or 2ON by and push
METHOD
ENT=OK
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
VAC TYPE
VAC & SEAL
1 OFF
Select
ENT=Go
2 ON
(Brinking number (
to
4 Put the cursor to "2 VAC&SEAL" and

Display changes to
/ MENU=Back
2 Change
4 Circulate
6 Maintain
Select the maintenance mode

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Set the cooling temperature

1-1 In the present operation number :
display changes to the one for setting
Press
each value and read 2.
Change
Move
Push

MENU /
1 Entry
3 Delete
5 Drain
Change
/ MENU=Back
2 Change
4 Circulate
6 Maintain
,
.
2 Put the cursor to "6 Maintain" by
and display changes to the one for
Press
selecting maintenance mode. ON or OFF.
(Initial state OFF as the following illustration.)
part is blinking.)
1-2 In the another operation number :

36, and select the number.
Then press
and read 2.
MAINTENANCE
Select
ENT=Go
1 OFF
2 ON
) is selected now.)
3 Put the cursor to 2 ON by

.
Move
(Brinking number (
part is blinking.)
and press
Display changes to maintenance mode.
two times.
In this condition, push
Cursor moves to the right side of "CT"
(blinking).
Adjust the value by
One degree is changed by one time push.

If kept on pushing, numeral change at high
speed.
(Setting range 100 F heating temperature)
(Setting range 40 C heating temperature)
O
MAINTENANCE
X
Y
( means ON
means OFF)
Refer to page 110 about the message of

maintenance mode.
T I PS
If cooling temperature is set extremely highly,
strong and beautiful seal cannot be made.
Please set the temperature suitable for the film.
Warning
If the extreme setting is going to be made, the

following warning is displayed on a liquid
crystal screen for 4 seconds.
WARNING!
Set cool temp
low enough
45
Select the 1 time gas flushing

/ MENU=Back
2 Change
4 Circulate
6 Maintain

Change" by
and push
Display changes to the one for selecting the

,
and push
METHOD
ENT=OK
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
4 Put the cursor to "3 1-GAS" by

.
and push
Display changes to
VAC TYPE
VAC & SEAL
1 Manual
46
2 Time
and push
T I PS
Please refer "Select the vacuum pattern" in
page 42.
2-1 Entry : Put the cursor to "1 Entry" by and

push
temperature.
Please set the suitable value.

MENU /
1 Entry
3 Delete
5 Drain
2 Time, 3 Gauge by
Display changes to the one for setting the

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push
5 Select the vacuum method from 1 Manual,
Select
3 Gauge
Set the 1 time gas flushing timer

1 Refer the explanation in page 44 and select
the 1 time gas flushing.
Then select the vacuum pattern as the
instruction in page 42.
2 Put the cursor to the position for setting the

gas flushing time.
Select the n-times gas flushing

SEALING ONLY
Change (number)
Change (item)
COUNTER
xxxxx
Push
part is blinking.)
Change
Move
Change" by
part is blinking.)
2-2 When you select "2 Time" or "3 Gauge",

put the cursor is under the position for setting
the flushing time by
In the case of "2 Time"
and push
and push
METHOD
ENT=OK
1 SEAL
2 VAC & SEAL
3 1-GAS
4 n-GAS
5 CIRCULATE
4 Put the cursor to "4 n-GAS" by

.
and push
part is blinking.)
Display changes to
Change
Move
VAC TYPE
n-GAS
1 Manual
Change
Move
Display changes to the one for selecting the

2-1 Entry : put the cursor to "1 Entry" by

and push
.
/ MENU=Back
2 Change
4 Circulate
6 Maintain
MENU /
1 Entry
3 Delete
5 Drain
2-1 When you select "1 Manual",the cursor is

already under the position for setting the gas
flushing time.
Change
Move
Select
2 Time
3 Gauge
part is blinking.)
5 Select the vacuum method from 1 Manual,

3 Set the gas flushing time by
(Setting range : 0.1 99.9 seconds)
2 Time, 3 Gauge by
and push
6 About the next setting, please refer "Set the

n-time gas flushing timer" in page 45.
47
Set the n-times gas flushing timer

T I PS
Two pattern's gas flushing time can be set.
1 : from the first time to (n-1) time
2 : n (the last) time
Ex. 5 times gas flushing :

1st and 5th time can be set.
2nd, 3rd, 4th time are same with 1st
Set the number of vacuum and gas flushing

,
times by
(Setting range : 2 99 times)

Put the cursor (by
2-1-3
position
1 Refer the explanation in page 45 and select

the n-times gas flushing.
Then select the vacuum pattern as the
instruuction in page 42.
2-1 When you select "1 Manual"
2-1-1 Set the 1st (to n-1th) gas flushing
time.
Change
Move
Change
Move
part is blinking.)
Put the cursor (by

2-1-2
position
), to the
for setting the number of vacuum and gas

flushing times. (the left of VT)
Change
Move
part is blinking.)
Change
Move
48
part is blinking.)
2-2 When you select "2 Time"

2-2-1 Set the 1st (to n-1th) vacuum time.
part is blinking.)
Set the gas flushing time by
Change
Move
Change
Move
part is blinking.)
part is blinking.)
), to the
for setting the n th (last) gas flushing time.
Change
Move
part is blinking.)
Change
Move
part is blinking.)
Set the vacuum time by
2-2-2 Set the 1st (to n-1th) vacuum time.

Change
Move
Change
Move
part is blinking.)
Set the vacuum time by
part is blinking.)

Change
Move
2-2-5 Set the n th gas flushing time.
part is blinking.)
Change
Move
Put the cursor (by

2-2-3
position
), to the

(the left of VT)
part is blinking.)
Change
Move
part is blinking.)
Set the gas flushing times by

,
times by
2-3 When you select "3 Gauge"

2-3-1 Set the 1st (to n-1th) vacuum degree.
Change
Move
part is blinking.)
Change
Move
2-2-4 Set the n th vacuum time.

Change
Move
1VT xx.xsec
G xx.xsec
xxVT xx.xsec
G xx.xsec
HT xx F
x.xs
CT xx F
O
part is blinking.)
Set the vacuum degree by
(Setting range : -1 -100 kpa)
part is blinking.)
49
2-3-2
time.
Set the 1st (to n-1th) gas flushing
Change
Move
Change
Move
part is blinking.)
part is blinking.)
Change
Move
Change
Move
2-3-4 Set the n th vacuum degree.
part is blinking.)
part is blinking.)
Set the vacuum degree by
2-3-5 Set the n th gas flushing time.

Put the cursor (by
2-3-3
position
), to the

(the left of VT)
Change
Move
part is blinking.)
Change
Move
Change
Move
(
Change
Move
50
part is blinking.)
part is blinking.)

time by
part is blinking.)
3 Display change to the one for setting the

temperature.
Please set the suitable value.
51
8-5 Operation procedure

In this chapter, the flow of 13 kinds operations are explained.
Please check the flow of how to use after setting up the controller.
Sealing only
Operation number
Change
HT xx F
x.xs
Move
CT xx F
O
Heating time
Cooling temperature
Heating temperature
Operation number
Change
HT xx C
x.xs
Move
CT xx C
O
Heating time
Cooling temperature
Heating temperature
Procedure
Reference page or Description
Circuit breaker ON.
"Starting of use" in page 34.
Power button ON.
3-1 Already entered, select the operation number

of "SEALING ONLY".
3-2 No entry :
3-1 "Select the operation number" in page 38.
Set the heating temperature.

O
O
"Set the heating temperature" in page 36.
Set the heating time.

(Setting range 0.0 2.0seconds)
"Set the heating time" in page 36.
Set the cooling temperature.
"Set the cooling temperature" in page 45.
3-2 "Select the sealing method" in page 38.

="1 SEAL"

O
O
52
Set a pouch on the sealing position.
Prepare both ends of a pouch for a seal position.
Depress the foot switch (1st).
Pressure lever descends and fasten a pouch with

sponge rubber. (Keep on stepping until the pressure
lever close.)
Attention
If leg is separated from the foot switch in the middle

of downward, the pressure lever will open for the safe
mechanism.
9
Depress the foot switch (2nd).
By the second depressing the foot switch, the following

process (from 9-1 to 9-5) is performed automatically.
9-1 Sealing starts.
9-2 Heating lamp is turned on.
9-3 After the heating is finished (heating lamp is turned

off), cooling lamp is turned on.
9-4 Cooling is finished. (Cooling lamp is turned off.)

(Pressure lever open.)
10
Sealing process is completed.
If you will not use this sealer for a long time, please
work as indicated in "Finishing of use" in page 34.
53
Vacuum (manual) and Sealing

Operation number
Change
1V MANUAL
HT xx F
O
x.xs
Move
Vacuum pattern = manual
CT xx F
O
Heating time
Cooling temperature
Heating temperature
Operation number
Change
1V MANUAL
HT xx C
O
x.xs
Move
CT xx C
O
Heating time
Cooling temperature
Heating temperature
Procedure
54
Circuit breaker ON.
Power button ON.
"Starting of use" inpage 34.

of "VAC&SEAL manual".
3-2 No entry :

3-2 "Select the sealing method" in page 38
= "2 VAC&SEAL"
= "1 Manual"

O
O


O
O
Depress the foot switch (1st)
Nozzle comes forward.
Insert the nozzle in a pouch, and set it on the sealing

position.

lever close.)
Attention

mechanism.
10
Depress the foot switch (3rd).
Vacuum process starts.Vacuum lamp is turned on.
11
When the sufficient vacuum is done, depress the

foot switch (4th).
By the fourth depressing the foot switch, the following

process (from 11-1 to 11-6) will be performed
automatically.
11-1 Vacuum is finished.
11-2 Nozzle returns.

11-3 Pressure lever close and sealing starts.
Heating lamp is turned on.
11-4 After the heating is finished (heating lamp is

turned off), cooling lamp is turned on.

(Pressure lever opens and nozzle comes forward.)
12
55
Vacuum (timer) and Sealing

Operation number
Change
1VT xx.xsec
HT xx F
O
x.xs
Move
Vacuum pattern = timer
and set-up value
CT xx F
O
Heating time
Cooling temperature
Heating temperature
Operation number
Change
1VT xx.xsec
HT xx C
O
x.xs
Move
and set-up value
CT xx C
O
Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "VAC&SEAL timer".
3-2 No entry :

= "2 VAC&SEAL"
= "2 Time"
Set the vacuum time.

"Set the vacuum time" in page 43.

O
O


O
O

position.
56
10

lever close.)
Attention

mechanism.
11
By the third depressing the foot switch, the following

automatically.
11-1 Vacuum starts. Vacuum lamp is turned on.
11-2 When the set-up time is passed, vacuum is

finished. Vacuum lamp is turned off.



12
57
Vacuum (gauge) and Sealing

Operation number
Change
1VG- xxkpa
HT xx F
O
x.xs
Move
Vacuum pattern = gauge
and set-up value
CT xx F
O
Heating time
Cooling temperature
Heating temperature
Operation number
Change
1VG- xxkpa
HT xx C
O
x.xs
Move
and set-up value
CT xx C
O
Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
"Starting of use" in page 34
Power button ON.

of "VAC&SEAL gauge".
3-2 No entry :

= "2 VAC&SEAL"
= "3 Gauge"
Set the vacuum degree.

(Setting range -1 -100kpa)
"Set the vacuum degree" in page 43.

O
"Set the heating temperature" in page 36

O


O
O
58

position.
10

lever close.)
Attention

mechanism.
11

automatically.
11-2 When the vacuum degree reaches to the set-up

time, vacuum is finished. Vacuum lamp is turned off.



12
59
[1 time] Vacuum (manual), Gas flushing and Sealing

Operation number
Change
Move
1V MANUAL
G xx.xsec
Gas flushing time

HT xx F
O
x.xs
CT xx F
O
Heating time
Cooling temperature
Heating temperature
Operation number
Change
Move
1V MANUAL
G xx.xsec
Gas flushing time

HT xx C
O
x.xs
CT xx C
O
Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "1-GAS manual".
3-2 No entry :

3-2 "Select the 1 time gas flushing" in page 46.
= "3 1-GAS"
= "1 Manual"
Set the gas flushing time.

"Set the 1 time gas flushing timer" in page 47.

O
O


O
O
60

position.
10

lever close.)
Attention

mechanism.
11
12

foot switch (4th).

automatically.
12-1 Vacuum is finished.Vacuum lamp is turned off.
12-2 Gas flushing starts. Gas flushing lamp is turned on.
12-3 Gas flushing is finished when set-up time is past.

Gas flushing lamp is turned off.



13
If you will not use this sealer for a long time, please work as
indicated in "Finishing of use" in page 34.
61
[1 time] Vacuum (timer), Gas flushing and Sealing

Operation number
Change
Move
1VT xx.xsec
G xx.xsec
HT xx F
O
x.xs
CT xx F
O
Gas flushing time

and set-up value
Heating time
Cooling temperature
Heating temperature
Operation number
Change
Move
1VT xx.xsec
G xx.xsec
HT xx C
O
x.xs
CT xx C
O
Gas flushing time

and set-up value
Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "1-GAS timer".
3-2 No entry :

= "3 1-GAS"
= "2 Time"

"Set the vacuum time" in page 43.


O
O


O
O
62
10

position.
11

lever close.)
Attention

mechanism.
12
By the third depressing the foot switch, the following process

(from 12-1 to 12-9) will be performed automatically.
12-2 Vacuum is finished when set-up time is past. Vacuum

lamp is turned off.
12-4 Gas flushing is finished when set-up time is past. Gas

flushing lamp is turned off.

12-7 After the heating is finished (heating lamp is turned off),

cooling lamp is turned on.

13
If you will not use this sealer for a long time, please work as
indicated in "Finishing of use" in page 34.
63
[1 time] Vacuum (gauge), Gas flushing and Sealing

Operation number
Change
Move
G xx.xsec
1VG- xxkpa
HT xx F
O
x.xs
CT xx F
O
Gas flushing time

and set-up value
Heating time
Cooling temperature
Heating temperature
Operation number
Change
Move
G xx.xsec
1VG- xxkpa
HT xx C
O
x.xs
CT xx C
O
Gas flushing time

and set-up value
Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "1-GAS gauge".
3-2 No entry :

= "3 1-GAS"
= "3 Gauge"

"Set the vacuum degree" in page 43.


O

O


O

O
64
10

position.
11

lever close.)
Attention

mechanism.
12

automatically.
12-2 Vacuum is finished when set-up time is past.

Vacuum lamp is turned off.
12-4 Gas flushing finished when set-up time is past.




13
65
[n times] Vacuum (manual), Gas flushing and Sealing

Vacuum pattern (from 1st to n-1th) = manual
Operation number
Change
Move
1V MANUAL
G xx.xsec
xx V MANUAL
G xx.xsec
HT xx F x.xs CT xx F
O
Vacuum method (n th) = manual

Gas flushing time (from 1st to n-1th)
Gas flushing time (n th)
Heating time
Cooling temperature
Heating temperature
Number of times for vacuum and gas flushing
Vacuum pattern (from 1st to n-1th) = manual
Operation number
Change
Move
1V MANUAL
G xx.xsec
xx V MANUAL
G xx.xsec
HT xx C x.xs CT xx C
O
Vacuum method (n th) = manual

Heating time
Cooling temperature
Heating temperature
Procedure
66
Circuit breaker ON.
Power button ON.

of "n-GAS manual".
3-2 No entry :

3-2 "Select the n-times gas flushing" in page 47.
= "4 n-GAS"
"Select the vacuum pattern" in page 44. = "1 Manual"
Set the 1st to n-1th gas flushing time.

Set the number of time for vacuum and gas

flushing.
(Setting range 2 99times)
Set the n-th gas flushing time.


O
O

"Set the n-times gas flushing timer" in page 48.

O
O
10
11

position.
12

lever close.)
Attention

mechanism.
13
14

foot switch (4th).

automatically.
Gas flushing starts. Gas flushing lamp is turned on.
14-2 Gas flushing is finished when set-up time is past.

14-3 The second vacuum starts.Vacuum lamp is turned on.
15

foot switch (5th).
Process from 14-1 to 14-3 is repeated n-1 times.
16
Depress the foot switch (n-th).
By the n-th depressing the foot switch, the following

automatically.
n-th Gas flushing starts. Gas flushing lamp is turned on.
67
16
16-2 n-th Gas flushing is finished when set-up time is past.




17
68
[n times] Vacuum (timer), Gas flushing and Sealing

Vacuum pattern (from 1st to n-1th) = timer
and set-up value
Operation number
Change
Move
1VT xx.xsec
G xx.xsec
xx VT xx.xsec
G xx.xsec
O
Vaccum method (n th) = timer and set-up value

Heating time
Cooling temperature
Heating temperature
Vacuum pattern (from 1st to n-1th) = timer
and set-up value
Operation number
Change
Move
1VT xx.xsec
G xx.xsec
xx VT xx.xsec
G xx.xsec
O
Vacuum method (n th) = timer and set up value

Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "n-GAS timer".
3-2 No entry :
Set the 1st to n-1th vacuum time.

Set the 1st to n-1th gas flushing time.

Set the number of times for vacuum and gas flushing

Set the n-1th vacuum time.

Set the n-1th gas flushing time.


O
O
3-2 "Select the n-times gas flushing" in page 47.

= "4 n-GAS"
"Select the vacuum pattern" in page 44. = "2 Time"
"Set the n-times gas flushing timer" in page 48
69
10

11

O
O
12
13

position.
14

lever close.)
Attention

mechanism.
15

automatically.
15-1 Vacuum starts (1st). Vacuum lamp is turned on.
15-2 Vacuum is finished when set-up time (for 1st

n-1th vacuum) is past. Vacuum lamp is turned off.
15-3 Gas flushing starts (1st).

Gas flushing lamp is turned on.
15-4 1st gas flushing is finished when set-up time (for

1st
n-1th gas flushing) is past.
15-5 Process 15-1
15-4 is repeated n-1 times.
15-6 The last (n-th) vacuum starts.

Vacuum lamp is turned on.
70
15

Vacuum lamp is turned off and n-th gas flushing starts.
15-8 n-th gas flushing is finished when set-up time is past.




16
71
[n times] Vacuum (gauge), Gas flushing and Sealing

Vacuum pattern (from 1st to n-1th) = gauge
and set-up value
Operation number
Change
Move
G xx.xsec
1VG- xxkpa
xx VG- xxkpa
G xx.xsec
O
Vacuum method (n th) = gauge and set-up value

Heating time
Cooling temperature
Heating temperature
Vacuum pattern (from 1st to n-1th) = gauge
and set-up value
Operation number
Change
Move
G xx.xsec
1VG- xxkpa
xx VG- xxkpa
G xx.xsec
O
Vacuum method (n th) = gauge and set-up value

Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "n-GAS gauge".
3-2 No entry :
Set the 1st n-1th vacuum degree.

Set the 1st n-1th gas flushing time.

Set the number of times for vacuum and gas flushing
3-2 "Select the 1 time gas flushing" in page 47

= "4 n-GAS"
"Select the vacuum pattern" in page 44. = "3 Gauge"
"Set the n-times gas flushing timer" in page 48.

7
Set the n-th vacuum degree.

Set the n-th gas flushing time.


O
O
72
10

11

O
O
12
13

position.
14

lever close.)
Attention

mechanism.
15

automatically.
15-1 Vacuum starts (1st). Vacuum lamp is turned on.
15-2 Vacuum is finished when set-up time (for 1st

n-1th vacuum) is past. Vacuum lamp is turned off.
15-3 Gas flushing starts (1st). Gas flushing lamp is

turned on.
15-4 1st gas flushing finished when set-up time (for 1st
n-1th gas flushing) is past.
15-5 Process 15-1 15-4 is repeated n-1 times.

15-6 The last (n-th) vacuum starts.
Vacuum lamp is turned on.
73
15

Vacuum lamp is turned off and n-th gas flushing starts.
15-8 n-th gas flushing is finished when set-up time is

past. Gas flushing lamp is turned off.



16
74
[Circulate] Vacuum (manual), Gas flushing and Sealing

Operation number
Change
Move
1V MANUAL
G xx.xsec
GCT xx.xsec
G xx.xsec
O
Circulatory gas flushing time

1st gas flushing time
2nd gas flushing time
Heating time
Cooling temperature
Heating temperature
Operation number
Change
Move
1V MANUAL
G xx.xsec
GCT xx.xsec
G xx.xsec
O

Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "Circulation manual".
Caution
Check the piping for gas circulation

(Switch to NC piping)
3-2 No entry :
4
Set the 1st gas flushing time.

Set the circulate gas flushing

Set the 2nd gas flushing time.


O
3-2 "Select the gas circulation " in page 39.
"Set the gas circulation / vacuum by manual" in page 40.

O

75

O

O
10
11

position.
12

lever close.)
Attention

mechanism.
13
Vacuum process starts. Vacuum lamp is turned on.
14

foot switch (4th).

automatically.
14-1 Vacuum is finished. Vacuum lamp is turned off.
14-2 1st gas flushing starts. Gas flushing lamp is turned on.
14-3 1st gas flushing is finished when set-up time is past.

14-4 Circulation starts.

Vacuum lamp and gas flushing lamp are turned on.
14-5 Circulation is finished when set-up time is past.

Vacuum lamp and gas flushing lamp is turned off.
14-6 2nd gas flushing starts. Gas flushing lamp is turned on.
76
14
14-7 2nd gas flushing is finished when set-up time is past.




15
If you will not use this sealer for a long time, please work
as indicated in "Finishing of use" in page 34.
77
[Circulate] Vacuum (timer), Gas flushing and Sealing

Vacuum pattern = timer and set-up value
Operation number
Change
Move
1VT xx.xsec
G xx.xsec
GCT xx.xsec
G xx.xsec
O

Heating time
Cooling temperature
Heating temperature
Vacuum pattern = timer and set-up value
Operation number
Change
Move
1VT xx.xsec
G xx.xsec
GCT xx.xsec
G xx.xsec
O

Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "Circulation timer".
Caution

3-2 No entry :
4





O
3-2 "Select the gas circulation " in page 39."
"Set the gas circulation / vacuum by timer" in page 41.

O
78

10

O

O
11
12

position.
13

lever close.)
Attention

mechanism.
14

automatically.
14-1 Vacuum process starts. Vacuum lamp is turned on.




79
14




15
80
[Circulate] Vacuum (gauge), Gas flushing and Sealing

Vacuum pattern = gauge and set-up value
Operation number
Change
Move
G xx.xsec
1VG- xxkpa
GCT xx.xsec
G xx.xsec
O

Heating time
Cooling temperature
Heating temperature
Vacuum pattern = gauge and set-up value
Operation number
Change
Move
G xx.xsec
1VG- xxkpa
GCT xx.xsec
G xx.xsec
O

Heating time
Cooling temperature
Heating temperature
Procedure
Circuit breaker ON.
Power button ON.

of "xx-Circulation gauge".
Caution

3-2 No entry :
3-2 "Select the gas flushing circulation" in page 39.





O
O
"Set the heating temperature" in page 36

"Set the gas circulation / vacuum by gauge" in page 42.
81
10

O
O
11
12

position.
13

lever close.)
Attention

mechanism.
14

automatically.
14-1 Vacuum process starts. Vacuum lamp is turned on.




82
14




15
83
Replacing the routine maintenance parts

Replace parts according to the following directions in order to maintain your machine in optimum operating
condition.
Warning
Always unplug power plug before replacing any parts. There is a danger of electrocution if
conducted with the plug still inserted.
Warning
Do not replace parts according to other methods not described in the operating instructions. It is
dangerous if incorrect methods are used.
Warning
When replacing parts, always use only specified parts sold through Fuji Impulse. Otherwise
malfunction may occur.
Always unplug power plug from

the wall outlet before
conducting any maintenance.
110V specification
220V specification
Construction of the sealing section

The sealing section is constructed with parts illustrated in the diagram at left. When replacing parts, be careful to
arrange the parts in the same exact order.
1
VG-602/402 sealing section structure
VG-602/402-10D sealing section structure

Pressure lever
Pressure lever
Silicone rubber
Silicone rubber
Glass tape 50mm
Glass tape 19mm
Glass tape 19mm

Heating element
Teflon sheet
Heating element
Temperature sensor
Glass tape 25mm
Sarcon sheet
Teflon sheet
Heating element
Temperature sensor
Glass tape 25mm
Sarcon sheet
Routine maintenance parts

As you use the sealer, the parts wear, sealing result worst., to continues operate with damage part will cause
malfunction, so please replace the wear parts on time with space parts always in hands.
The routine maintenance parts are selling by the unit described below
Order from your dealer, specifying the name of your machine, the name and quantity of parts you need.
Parts name
Heating element (5mm,10mm)
Teflon sheet
Silicone rubber
Glass tape
Sarcon sheet
Plastic nut (white)
84
Selling unit
10pcs. per set / 20pcs. per set
2sheets per set
2pcs. per set
5M roll or 10M roll
2sheets per set or 5M roll
5pcs. per set
5M roll
9-1 Sliding teflon sheet
Teflon holder
[Replace when]
When the teflon sheet is torn, burnt or sealing is dirty
[Essential tools]
Scissors
1 Loose the four resin nuts (white) securing the

teflon holder and sponge holder.
2 Turn the teflon sheet winding rod. Wind the damaged

teflon sheet forward or backward for 15mm.
3 When the teflon sheet is loosen, hold the teflon
winding rod and tight the resin nuts to fix the
teflon holder and sponges holder.
When the teflon sheet is sticking to the heater wire,

peel it off before winding. 25 to 30cm of teflon
sheet is wound for a space, if the sheet remain a
little or consumed, refer "changing the teflon
sheet" to change the teflon sheet.
Sponge holder
Plastic nut (white)
Teflon winding rod
9-2 Replacing teflon sheet

[Replace when]
When the teflon sheet is torn, burnt or sealing is dirty
[Essential tools]
Scissors
Teflon holder
1 Unscrew the resin nuts (white) securing the teflon

holder and sponge holder.
2 Remove the teflon holder and sponge holder, then
peel off teflon sheet from the teflon winding rod.
3 Strike the new teflon sheet by cellophane tape on
teflon sheet.
4 Screw the 4pcs. resin nut (white) lightly. Hold the
teflon winding rod by sponge holder and teflon
Sponge holder
Plastic nut (white)
Teflon holder
spring
Teflon winding rod
holder.
Teflon sheet
5 To avoid wrinkles of teflon sheet above the

heating element, winding the teflon rod to smooth
the teflon sheet.
Cellophane tape
Teflon winding rod
6 Screw the 4pcs. resin nut (white) to push the

teflon holder to fix the teflon winding rod.
85
9-3 Replacing center-dry tape on

the upper lever
(object : double side heating model)
To change the teflon center dry tape attached on the
pressure plate.
Pressure lever
1 Take off the frame cover.

2 Remove the both right and left side E-ring of the
pressure lever by (minus) screwdriver, and pull out
the pin.
E-ring
Pin
(Minus) Screw driver
3 Raise up the pressure lever and remove the sponge

rubber.
Sponge rubber
4 Remove the teflon center dry tape.

Direct paste the new one's adhesive tape to the
pressure lever.
Insert one side of the center dry tape into the gap
that in between the pressure lever and sponge
holder.
Attention
When you could not paste smoothly, insert

thin ruler between the sponge holder and
pressure plate. Then slide the center dry
tape with pushing it on the pressure plate.
5 Cut excess by scissors.
Sponge holder
Pressure plate
6 Fold the other side of the tape that attached

adhesive tape to the opposite side of sponge holder.
Attention
86
Caution when replace the tape:

Place the center space of the tape on the
heating element.
If the wrinkles remain on the dry tape, it will
be printed on the seal bag.
9-4 Replacing heating element

[Replace when]
The heating element has burned out. Sealing is dirty or
uneven.
[Essential tools]
Heating element
1 The heating element is covered with the teflon

sheet. Remove the teflon sheet, referring to
"changing the teflon sheet"
Heater securing screw
2 The electrode cover is screwed on the side.

Loosen the screw with a Phillips screwdriver and
pull to remove it.
3 Raise the electrode lever up to loosen the heating

element. Loosen the heater securing screw with a
Phillips screwdriver.
4 Loosen the screw and remove the wearied heating

element.
5 When the electrode lever is raised, insert the new
heating element into the groove of electrode,
tighten the securing screw to secure the element
while pressure the heating element so that it does
not slip from the electrode. After tighten the
securing screw, push down the electrode lever.
Caution
Electrode cover
securing screw
Electrode lever
Electrode cover
For your safety always reattach the

electrode cover after installing the heating
element.
Use a heating element specified for this
model. Using a different element may
cause transformer failure.
When heating element is exchanged to another width

This machine is shipped with 10mm width heating
element, and set up to the optimal sealing conditions
(heating temperature, heating time, cooling
temperature).
Since seal conditions change when the width is

changed, please set up again, perform a seal test, and
adjust to the optimal value.
Conversely, when 5mm width is changed into 10mm
width, please work similarly.
87
9-5 Replacing glass tape(19mm

width, 25mm width), sarcon sheet
[Replace when]
The heating element is often burnt out. Sealing is dirty
[Essential tools]
Phillips screwdriver; Scissors; Alcohol (Ethanol)
Caution
If the glass tape or sarcon sheet blow the

heating element is burnt, the heater wire
itself may short circuit and melt or proper
seals may not be attained. Inspect them
when replacing heating element, if
necessary change them.
lenght of
sealing section
Electrode
Sarcon sheet
about 5mm
1 Remove the teflon sheet and heating element.

2 Peel the glass tape and sarcon sheet located below
the heating element completely off.
3 Some adhesive remain will uneven the sealing
surface, and has an adverse effect, please clean the
surface thoroughly before applying the glass tape
and sarcon sheet.
about 2mm
about 2mm
about 5mm
Glass tape
4 Attaching a new sarcon sheet along the length of

sealing section. (One sheet)
5 Attaching a glass tape on the sarcon sheet, the
glass tape must be about 5mm longer than the
sealing section. (One sheet)
9-6 Replacing silicone rubber

(object single side heating model)
[Replace when]
Silicone rubber is uneven

[Essential tools]
Alcohol (Ethanol)
1 Remove two glass tape attached on the pressure

lever.
2 Remove the silicone rubber. Wipe the adhesive

tape off the pressure lever with alcohol (Ethanol).
Attaching the silicone rubber on the top of
remained adhesive will has an adverse effect to
sealing.
3 The silicone rubber has an adhesive tape on it,

peel the paper and attach the new silicone rubber
carefully, starting from one end.
4 After attaching the silicone rubber, attach two
pieces of glass tape (50mm 19mm width) on it.
88
Pressure lever
Silicone rubber
Glass tape 50mm width
9-7 Replacing silicone rubber

(object : double side heating model)
[Replace when]
Silicone rubber is uneven
[Essential tools]
Alcohol (Ethanol)
1 Remove the center dry tape, heating element, and

glass tape according to the each instructions.
2 Remove the silicone rubber, and wipe the

adhesive tape off the pressure lever with alcohol
(Ethanol).
Attaching the new silicone rubber on the remained
Pressure lever
3 The silicone rubber has an adhesive tape on it.

Peel the paper and attach the new silicone rubber
carefully, starting from one end.
Center dry teflon tape
Silicone rubber
adhesive tape will has an adverse effect to sealing.
Heating element
4 After attaching the Silicone rubber, attach on it in

order of the sarcon sheet, glass tape (19mm width),
heating element and center dry tape.
9-8 Replacing 50mm width glass tape

(object single side heating model)
1
Pressure lever
[Replace when]
The heating element is often burn out. Sealing is dirty.
[Essential tools]
Scissors
Silicone rubber
1 After attaching the silicone rubber, attach a 50mm

width piece of glass tape on the silicone rubber so
2 Fold this excess upward.

3 Fold the corners inward as shown in the figure.
Fold upward
that the glass tape extend about 2cm from the end
of the pressure lever.
4 Attach the tape onto the sides of the pressure

lever.
5 Attaching the 19mm width glass tape from above

as shown in the illustration.
Fold the surplus inside
6 Fold the excess 2mm upward onto the pressure

lever.
Paste to the pressure lever
5
6
Fold upward
89
9-9 Connecting and removing tube

When remove the tube, press the release ring while
pushing the tube.
Body
Pay attention to the distance

between the release ring and body
1921mm
Release ring
press there to remove the tube
Tube
How to remove the tube

If you press the release ring while pushing the tube in at
the same time, you can remove the tube quite easily.
Nut
section
V elastic sleeve
O ring
How to connect the tube

Insert the tube fully to the tube end of the joint.
Release ring
Attention
To avoid the air leakage, please verify the

tube is jointed firmly.
9-10 Replacing microswitch

[Essential tools]
1 Take off the cover on the left side of frame by a
Phillips screwdriver.
2 Remove the two screws which fasten the
microswitch, and pick up microswitch.
Microswitch
3 Take off the microswitch cover.

Remove the wiring with a Phillips screwdriver and
exchange the microswitch.
Caution
Connect the wiring so that the display on

microswitch (COM, NO) accord to the
display on the mark tube of lead wire.
Microswitch cover
90
Mark tube
Lead wire
9-11 Replacing nozzle

[Essential tools]
Spanner
1 Take off the frame cover.

2 Remove the elbow from the nozzle.
Push the open ring to horizontal direction with
nozzle, then lock will be cancelled.
Elbow
Nozzle supporter
Open ring
3 Loosen the bolt on the of nozzle supporter by the

spanner.
4 Extract the nozzle from the nozzle supporter.
91
9-12 Replacing temperature sensor

for VG-602 series
[Replace when] Temperature sensor is damaged.
ScrewA-1
Temp.sensor fixing plate
[Essential tools] Phillips screwdriver

Temperature sensor is set between glass tape and heating
element, and located to the right-hand end of the seal- receiving plate.
ScrewA-2
1 Remove the teflon sheet.

2 Remove the heating element. (Refer to page 85.)
Temperature sensor
module
3 Unfasten the screw A-1, A-2 to remove the temperature sensor fixing plate, and unfasten the
screw B. Temperature sensor can be removed.
4 Insert the protuberance of sensor fixing plate
(screw A-1 side) into the tip (hole) of new temperature sensor and seal frames hole.

Then fasten screw A-1.
Temperature sensor

(A-1 side)
ScrewA-1
5 Set the other sensor fixing plate and temporarily

fasten the screw A-2.

(Refer to the right illustration.)
Please take care not to make a slack of

sensor between screw A-1 and A-2.
Caution
6 Pull the temperature sensor module lightly to

keep the tension of temperature sensor and fix
the plate by screw A-2.
Slack
ScrewA-2
(A-2 side)
If the temperature sensor module would be

pulled strongly, sensor might be broken.
Caution
Slack
Temperature sensor
module
7 Fix the temperature sensor module by screw B.

8 Re-attach the heating element. (Refer to page
85.)
If the temperature sensor isnt installed on
the proper position, seal function might not
work.
Caution
Attention
Install the new temperature sensor so that

the perception part touches with the center
of heating element. (Refer to the right illustration.)
If the perception part is slipped off, temperature could not be detected exactly.
Proper position of temperature sensor
.Temperature sensor
.Position
Perception part
Heating element
Perception part
Install the sensor under the heating element
92
9-13 Replacing temperature sensor

for VG-402 series
[Replace when] Temperature sensor is damaged.
[Essential tools] Phillips screwdriver
Screw A-2
Screw B Temperature
sensor
Screw A-1
Temperature sensor is set between glass tape and heating

element, and located to the right-hand end of the seal- receiving plate.
1 Remove the teflon sheet.
2 Remove the heating element. (Refer to page 85.)
3 Unfasten the screw A-1, A-2 to remove the temperature sensor fixing plate, and unfasten the
screw B. Temperature sensor can be removed.
4 Insert the protuberance of sensor fixing plate
(screw A-1 side) into the tip (hole) of new temperature sensor and seal frames hole.

Then fasten screw A-1.
Temperature sensor

(A-1 side)
ScrewA-1
5 Set the other sensor fixing plate and temporarily

fasten the screw A-2.

(Refer to the right illustration.)
Please take care not to make a slack of

sensor between screw A-1 and A-2.
Caution
6 Pull the temperature sensor module lightly to

keep the tension of temperature sensor and fix
the plate by screw A-2.
Slack
ScrewA-2
(A-2 side)
If the temperature sensor module would be

pulled strongly, sensor might be broken.
Caution
Slack
Temperature sensor
module
7 Fix the temperature sensor module by screw B.

8 Re-attach the heating element. (Refer to page
85.)
If the temperature sensor isnt installed on
the proper position, seal function might not
work.
Caution
Attention
Install the new temperature sensor so that

the perception part touches with the center
of heating element. (Refer to the right illustration.)
If the perception part is slipped off, temperature could not be detected exactly.
Proper position of temperature sensor
Temperature sensor
Position
Perception part
Heating element
Perception part
Install the sensor under the heating element
93
10 Specification
10-1 Safety mechanism specifications
VG-402-xx
VG-402-xx-10D
110V
220V
Power source
Maximum power
2.0KW (10m heater)
consumption
1.1KW (5mm heater)
Power cord
VG-602-xx
VG-602-xx-10D
220V
220V
3.0KW (10m heater)
2.6KW
3.1KW
1.9KW (5mm heater)
CT.2x3x5M 3P 20A125V
CT.2x3x5M 3P 20A250V
Vacuum degree
-1
Vacuum method
-100Kpa
By nozzle (Method can be selected from vacuum gauge, timer or manual.)
Vacuum time
0.1
Gas flushing time
0.1
99.9sec
99.9sec
Driving style
Air cylinder
Plug
Sealing style
Single heating
Sealing length
Dual heating
Single heating
Sealing width
5 or 10mm
600mm
10mm
Height of sealing
surface
5 or 10mm
Driving style for sealing
30 degree
Air cylinder 63mm X 2
Sealing heating
temperature
480 F / 60
140
Sealing heating time
0.0
Sealing cooling
temperature Note1
100 F (40 C)
O
*
Machine weight Note2
*
93kg
Outside dimensions
Note3
250 C
O
2.0seconds
set up heating temperature
98kg
100kg
105kg
W595 X L555 X H1052mm
W675 X L555 X H1052mm
W400 X L315mm
W600 X L450mm
Table dimensions
*
*Note2
*Note3
10mm
932mm (from bottom to sealing surface)
Sealing angle
Note1
Dual heating
400mm
Please set lower value than heating temperature. If it is near the heating temp, cooling process is insufficent and teflon is damaged too much.
Machine weight doesnt contain the one of table and options. (Vacuum pump and air compressor / standard type)
When sealing suface is horizontal position.
10-2 Safety mechanism specifications

Overheating proof mechanism
a) Circuit breaker automatically turn OFF when heater has been heated over 3.5seconds.
b) When heating temperature doesnt reach to set-up value within 3seconds, the electricity
is stopped and error message appears on the display.
Lever driving style
Spring guides the lever when it is closing ; 63 cylinder guides when sealing.
Reset in emergency
The lever opens when foot switch is released while the lever is closing.
Abnormality response
In the foreign object (ex. fingers) prevent the sealer to act next movement when lever is
closing, automatically reset the sealer, after 1second the sealer is in initial state.
Emergency stop
In emergency stop switch is pushed when abnormality might generate, the circuit breaker
is turned OFF, power supply is intercepted and lever returns to the initial state.
Heating signal
Heating when levers closed ; microswitch guides the lever to going down (double safety
structure).
94
10-3 Appearance dimensions drawing
Unit ; mm
30o
(450)
Max. height 1238
): measurement of VG-602 series.
350
400
(600)
(988)
1052
932
105
888
595
(675)
92
95
10-4 Combination of vacuum pump and air compressor
VG series sealer is named by the combination

of vacuum pump and air compressor.
ex.
Compressor : MP-40 (called A)
Vacuum pump : DOP-80 (called H)
602 series dual heating type
VG-602-AH-10D
Vacuum pump / 4 types
Air compressor / 3 types
H.
A.
DOP-80SA : Piston type

For standard
Pumping speed : 80L/min
Ultimate pressure : -96KPa
Pump weight : 7kg
D.
G-50SA : Oil rotation type
For high vacuum degree
(small size pouch)
Ultimate pressure : -101.3KPa
Pump weight : 11kg
E.
G-100S : Oilrotation type
(large size pouch)
Pump weight : 22kg
G.
DA-60S : Diaphragm type
For clean room
(clean degree : about 10,000)
Pump weight : 12kg
96
MP-40 : Piston type

For standard
Usual pressure : 310-330 KPa
Relief valve set-up pressure
Weigh : 8kg
B.
DOA-P108-DB :
Diaphragm type
For clean room
Weigh : 7kg
C.
Air is provided by the out
side compressor
Suitable compressor
specification
0.75kw (80L/min) above
480KPa
10-5 Specifications by the combination of vacuum pump and air

compressor
Specifications by the combination of vacuum pump and air compressor
Standard VG series sealer has MP-40 compressor and DOP-80SA pump.
Ultimate pressure : 0 torr = -101.3kpa
Vacuum pump capacity is measured before it is assembled.
Air compressor : MP-40 pumping speed : 33L/min usual pressure : 3.1kgf/cm2 relief valve set-up pressure weight : 8kg
Standard type
Model
Vacuum pump
Pumping speed
Ultimate pressure
Pump weight
7kg
7kg
VG-602-AH VG-402-AH
DOP-80SA
80L/min
-96KPa
VG-602-AH-10D VG-402-AH-10D
DOP-80SA
80L/min
-96KPa
11kg
VG-602-AD VG-402-AD
G-50SA
50L/min
-101.3KPa
VG-602-AD-10D VG-402-AD-10D
G-50SA
50L/min
-101.3KPa
11kg
VG-602-AE VG-402-AE
G-100S
100L/min
-101.3KPa
22kg
VG-602-AE-10D VG-402-AE-10D
G-100S
100L/min
-101.3KPa
22kg
VG-602-AG VG-402-AG
DA-60S
60L/min
-80KPa
12kg
VG-602-AG-10D VG-402-AG-10D
DA-60S
60L/min
-80KPa
12kg
Air compressor : DOA-P108-DB pumping speed : 33L/min usual pressure : 3.1kgf/cm2 relief valve set-up pressure weight : 7kg
Clean room type
Vacuum pump
Pumping speed
Ultimate pressure
Pump weight
VG-602-BH VG-402-BH
Model
DOP-80SA
80L/min
-96KPa
7kg
VG-602-BH-10D VG-402-BH-10D
DOP-80SA
80L/min
-96KPa
7kg
VG-602-BD VG-402-BD
G-50SA
50L/min
-101.3KPa
11kg
VG-602-BD-10D VG-402-BD-10D
G-50SA
50L/min
-101.3KPa
11kg
VG-602-BE VG-402-BE
G-100S
100L/min
-101.3KPa
22kg
VG-602-BE-10D VG-402-BE-10D
G-100S
100L/min
-101.3KPa
22kg
12kg
12kg
VG-602-BG VG-402-BG
DA-60S
60L/min
-80KPa
VG-602-BG-10D VG-402-BG-10D
DA-60S
60L/min
-80KPa
Air compressor : out side suitable compressor specification : 0.75kw (80L/min), 490kpa above
Suitable compressor should be purchased separately
Vacuum pump
Pumping speed
Ultimate pressure
Pump weight
VG-602-CH VG-402-CH
Model
DOP-80SA
80L/min
-96KPa
7kg
VG-602-CH-10D VG-402-CH-10D
DOP-80SA
80L/min
-96KPa
7kg
VG-602-CD VG-402-CD
G-50SA
50L/min
-101.3KPa
11kg
VG-602CD-10D VG-402-CD-10D
G-50SA
50L/min
-101.3KPa
11kg
VG-602-CE VG-402-CE
G-100S
100L/min
-101.3KPa
22kg
VG-602-CE-10D VG-402-CE-10D
G-100S
100L/min
-101.3KPa
22kg
VG-602-CG VG-402-CG
DA-60S
60L/min
-80KPa
12kg
60L/min
-80KPa
12kg
VG-602-CG-10D VG-402-CG-10D
DA-60S
97
11 Specifications of accessories
11-1 Air parts
Parts name
Type
Standard life and remarks
Lever cylinder (big) X2pcs
Cylinder CDQ2B63-30D-F9BVS
500,000 times or 3 years
Lever cylinder (small)
Cylinder CDQ2B32-25
Vacuum nozzle cylinder
Cylinder CDM2BZ25-75A-H7BS
Lever cylinder electro-
Valve VK3120-1H-01
magnetic valve
Valve VK332-1H-01
Nozzle cylinder electro-
Valve VK3120-1H-01
Valve 126E1-21
Valve 200E1-21
magnetic valve
Gas nozzleelectroelectro-magnetic valve
Air electro-magnetic valve
Dry filter
Dry filter M-103 (first) : black
2 years
Dry filter M-103 (second) : red
Half a year
11-2 Electric parts

Name
Circuit breaker with S-6
Type and model
Standard life and remarks
Circuit breaker GB-2Z
10,000 times (6 times / min)
S-6 safety circuit board
500,000 times or more (relay on board)
SSR-03 relay
SSR-03
10 hours or more (on contact)
Relay in micro computer
FTR-F3AA024E-HA5A
5,000,000 times or more
Lever lower position MS
Microswitch BA-2RQ1-T4-J
100,000 times or more (on contact)
Cooling fan
Fan 4715MS-10T-B50
Average life 3,000 hours

(consecutive operation)
Sealing transformer
Transformer V-400-5/10
Out of rating
Power cord (110V)
CT2X3X5M 3P 20A125V
Out of rating
Power cord (220V)
CT2X3X5M 3P 20A250V
Out of rating
Foot switch
Switch OFL-V-SP
500,000 times or more
Other
1 Although life of sealing portion or slide portion in the machine differs by frequency of use,
exchange is needed every three or four year.
2 Piping tube discolor and harden by surrounding temperature or humidity.
As it cause an air leak, please replace the tube regularly.
3 In addition to the standard life, when surroundings are dusty, please clean or exchange valve and
filter.
4 Also about the electric parts, cleaning or exchange is needed with surrounding situation (humidity,
dust, or usage) in addition to the standard life.
98
12 Regular check and maintenance

For longer the sealer life and normally operation, it is necessary to check and maintain the sealer regularly.
Please perform the checking and maintenance on time after purchased the sealer.
12-1 Regular check

Checking items for every day
Sealing surface
Veryfy that teflon sheet and silicone rubber are not dirty or damaged.
Air filter
Remove the filter cup and clean it. (Ref. next page)
Checking items for every week

Teflon sheet
If it is damaged or color is changed, slide the teflon or replace with new one.
Heating element
If it is damaged or color is changed, replace with new one.
Air filter element
If it is dirty, clean by flowing air.
Dry filter
If it is dirty, clean the clogging. (Ref. related instruction)
Checking item for every month

Glass tape
If it is damaged or color is changed, replace with new one.
Sarcon sheet
If it is not damaged or color is changed,replace with new one.
Vacuum tube section
Verify that there is no any foreign object in joint and horse.
Checking items per year

Silicone rubber
If it is not burned or damaged, replace with new one.
Relief valve
Verify the initial pressure setting is 320kpa. If not so, adjust it.
Cylinder
Verify the cylinder action is smooth. Otherwise, replace it.
Valve
Verify the valve action is smooth. Otherwise, replace it.
Temperature sensor *1
Verify the sensors tape color is not changed.
Checking main parts every three years

Air parts
Cylinder, Valve, Air tube, Air filter, Relief valve, Speed control valve
Electric parts
SSR-03 relay, circuit beaker, electrode
*1 Temperature which sensor recognize is adjusted to the actual heating temperature at the shipment from our
factory. But the error may occur for long time use, so please check it.
Ref. "Replacing the routine maintenance parts in page 82
99
12-2 Cleaning the air filter

The air filter is located in-between the nozzle and the
vacuum pump, stores any foreign objects accidentally
taken in though the nozzle in filter cup.
Be sure to check and clean cup everyday before the
operation.
Only in the case of a liquid (water), it drains

automatically if auto-drain system is turned on.
This drainage process is performed at each sealing,
so cup is not covered with water. However, the
amount of suction for one time is about 100ml (about
1/3 of cup). If the foreign objects reaches to 1/3 line
(in Figure 1), please exhaust them and clean the cup.
Removing the filter cup

Take off two plastic nut (black) and pull the cup
flange downward.
Filter cup can be removed.
(Filter cup and is stuck to cup flange by o-ring.)
Figure 1
To vacuum pump From nozzle
1/3 line
Drain valve Close
Taking apart and clean the air filter

If the filter element or filter cup becomes dirty, wash
them and install again after making them dry fully.
Please exchange for the new filter element every
three months (on the standard).
Caution
100
If too liquid is taken in, the liquid will

overflow the filter element and spill into the
vacuum pump, which may cause damage
of the pump.
Be careful not to take in over 100ml (about
1/3 of cup) at once.
If the overflow might occur, please
exchange the vacuum pump oil.
Filter element
Fixing bolt (SUS)
Element cap
Wing nut M4
O-ring
Filter cup
O-ring
Cup flange
Plastic nut (black)
Drain tube
Open
101
13 Electric diagram
13-1 Electric diagram for 110V
Object : VG-402-xx
Type (xx) : AH, AD, AE, CH, CD, CE
A
0V
105V
K J
8A
7A
6A
5A
4A
3A
8B
7B
6B
5B
4B
3B
2B
2A
1B
1A
L
K
Clear
Lamp
6
5
4
3
Red Lamp
1
Trans
former
S
heater
To Y0
Nozzle forward
SOL.Y4
Y4
Lever Hold in lower
SOL.Y3
Y3
Lever Hold in middle
SOL.Y2
Y2
Lever Down
SOL.Y1
Y1
IN304
SOL.Y5
IN
AC100V
OUT303
Vacuum Valve
NC
Y10
IN403
SOL.Y10
OUT401
Y11
COM
C19
NC
Y18
X19
Y17
X18
IN404
COM
C1
X15
COM
COM
VS
Vacuum pump
TC
24V
Vacuum Gauge
5V
24
GND
AD0
24V
AD3
96
Note) Not used in

outside piping type
GND
AD
98
Compressor
X16
C2
AD2
2 4 6
FAN
X17
C0
GND
95
X11
X10
5V
C2
97
Temprature
sensor
GND
AD5
AD1
Black
(Remark1)
The shape of power plug 2P20A is:
White
Green(Ground)
102
X12
C1
OUT402
Vacuum pump
auxiliary relay
Foot Switch
X13
Y16
C1
Lever Upper position
X0
X14
Y15
11 12 13 1
Lever Middle position
X1
Y13
SOL.Y11
Lever Lower position
X2
Y14
Y12
Gas flushing valve open
Nozzle Back position
X3
COM
C0
Water drainage valve open
X4
COM
Y0
To SSR No.4
Temprature
sensor
X5
Safety
micro-switch
Micro
switch
NO
SSR
OUT
AC100V
Y5
Safety
circuit
A
COM
Circut
breaker
110V
Printer
Outlet
AC110V
Ground
Terminal
13-2 Electric diagram for 220V

Object : VG-602-xx, VG-602-xx-10W, VG-402-xx-10W
Type (xx) : AH, AD, AE, CH, CD, CE
A
0V
105V
K J
8A
7A
6A
5A
4A
3A
8B
7B
6B
5B
4B
3B
Safety
circuit
A
Circut
breaker
220V
Printer
Outlet
AC220V
Ground
Terminal
2B
2A
1B
1A
L
K
COM
Clear
Lamp
Micro
switch
NO
6
5
4
3
SSR
Safety
micro-switch
Red Lamp
Trans
former
S
heater
To Y0
SOL.Y5
SOL.Y4
Y4
Lever Hold in lower
SOL.Y3
Y3
SOL.Y2
Y2
Lever Down
SOL.Y1
Y1
OUT303
Vacuum Valve
Nozzle forward
Y10
IN403
Y11
SOL.Y10
COM
C19
NC
Y18
X19
Y17
X18
IN404
COM
X15
COM
COM
VS
Vacuum Gauge
TC
5V
24
24V
AD0
24V
Vacuum pump
GND
Note) Not used in

outside piping type
GND
AD3
96
Compressor
X16
C2
AD
98
FAN
X17
C0
AD2
2 4 6
X11
C1
GND
95
X12
X10
5V
C2
97
Foot Switch
C1
OUT402
Vacuum pump
auxiliary relay
X0
X13
Y16
C1
X14
Y15
11 12 13 1
X1
(In the cace of double)
NC
OUT401
X2
Y13
SOL.Y11
X3
Y14
Y12
COM
C0
Water drainage valve open
X4
COM
Y0
To SSR No.4
X5
IN
AC100V
IN304
OUT
AC100V
Y5
Temprature
sensor
Temprature
sensor
GND
AD5
AD1
Black
(Remark1)
White
Green(Ground)
103
13-3 Electric diagram for 110V (without draining device)

Object : VG-402-xx
Type (xx) : AG, BG, CG
A
0V
105V
K J
8A
7A
6A
5A
4A
3A
8B
7B
6B
5B
4B
3B
2B
2A
1B
1A
L
K
Clear
Lamp
6
5
4
3
Red Lamp
1
Trans
former
S
heater
To Y0
Nozzle forward
SOL.Y4
Y4
Lever Hold in lower
SOL.Y3
Y3
SOL.Y2
Y2
Lever Down
SOL.Y1
Y1
IN304
SOL.Y5
IN
AC100V
OUT303
Vacuum Valve
Y10
COM
C19
NC
Y18
X19
Y17
X18
X15
COM
96
COM
Vacuum pump
Vacuum Gauge
TC
5V
24
24V
AD0
24V
AD3
GND
Note) Not used in

outside piping type
GND
VS
98
Compressor
X16
C2
GND
FAN
X17
C0
AD2
2 4 6
IN404
COM
C1
AD
95
X11
X10
5V
C2
97
Temprature
sensor
GND
AD5
AD1
Black
(Remark1)
White
Green(Ground)
104
X12
C1
OUT402
Vacuum pump
auxiliary relay
IN403
X13
Y16
C1
Foot Switch
X14
Y15
11 12 13 1
X0
NC
OUT401
X1
Y13
Y11
X2
Y14
Y12
SOL.Y10
X3
COM
C0
X4
COM
Y0
To SSR No.4
Temprature
sensor
X5
Safety
micro-switch
Micro
switch
NO
SSR
OUT
AC100V
Y5
Safety
circuit
A
COM
Circut
breaker
110V
Printer
Outlet
AC110V
Ground
Terminal
13-4 Electric diagram for 220V (without draining device)

Object : VG-602-xx, VG-602-xx-10W, VG-402-xx-10W
Type (xx) : AG, BG, CG
A
0V
105V
K J
8A
7A
6A
5A
4A
3A
8B
7B
6B
5B
4B
3B
Safety
circuit
A
Circut
breaker
220V
Printer
Outlet
AC220V
Ground
Terminal
2B
2A
1B
1A
L
K
COM
Clear
Lamp
Micro
switch
NO
6
5
4
3
SSR
Safety
micro-switch
Red Lamp
Trans
former
S
heater
To Y0
SOL.Y5
SOL.Y4
Y4
Lever Hold in lower
SOL.Y3
Y3
SOL.Y2
Y2
Lever Down
SOL.Y1
Y1
OUT303
Vacuum Valve
Nozzle forward
Vacuum pump
auxiliary relay
Y10
IN403
X10
C19
NC
Y18
X19
Y17
X18
IN404
COM
X15
COM
COM
VS
AD0
Vacuum Gauge
24V
TC
5V
24
24V
Note) Not used in

outside piping type
GND
Vacuum pump
GND
Compressor
X16
C2
AD3
96
FAN
X17
C0
AD
98
X11
COM
AD2
2 4 6
X12
C1
GND
95
Foot Switch
C1
5V
C2
97
X0
X13
Y16
C1
X1
X14
Y15
11 12 13 1
X2
Y13
OUT402
X3
(In the cace of double)
NC
OUT401
SOL.Y10
Y14
Y11
X4
COM
C0
Y12
COM
Y0
To SSR No.4
X5
IN
AC100V
IN304
OUT
AC100V
Y5
Temprature
sensor
Temprature
sensor
GND
AD5
AD1
Black
(Remark1)
White
Green(Ground)
105
14 Piping diagram
14-1 Piping diagram for VG-602/402 series with air compressor and
vacuum pump
Type : AH, AD, AE
Vacuum
gauge
CDQ2B63-30DF9BVS
CDM2BZ25-75A-H7BS
Nozzle
Sealing
section
Cylinder
(small)
Nozzle cylinder
Gas cock
Cylinder (big)
LS.X4
Cylinder (big)
LS.X1
126E1-21
SOL.Y10
CQ2B32-25
LS.X3
LS.X2
Filter
CDQ2B63-30DF9BV
Circulation
switch valve
Air
regulator
Rapid exhaust
valve
Filter
SOL.Y4
SOL.Y11
PK0802-NC
SOL.Y3
SOL.Y2
O
I
SOL.Y1
Chuck valve
Exhause
VK3120-1H-01 x 2
VK332-1H-01 x 2
Tube Length 8x2M
Exhause from
substance
Twinned
dry filter
Relief
valve
SOL.Y5
VX2330-03-1G
Compressor
Exhause
Tube Length
12x1.5M
106
Vacuum Pump
vacuum pump (Air is provided by the outside compressor)
Type : CH, CD, CE
Vacuum
gauge
CDQ2B63-30DF9BVS
CDM2BZ25-75A-H7BS
Nozzle
Sealing
section
Cylinder (big)
Nozzle cylinder
Gas cock
Cylinder
(small)
LS.X1
LS.X4
Cylinder (big)
126E1-21
SOL.Y10
CQ2B32-25
LS.X3
LS.X2
Filter
CDQ2B63-30DF9BV
Circulation
switch valve
Air
regulator
Rapid exhaust
valve
Filter
SOL.Y11
Draining Water
Equipment
PK0802-NC
SOL.Y4
SOL.Y3
SOL.Y2
O
I
SOL.Y1
Exhause
Tube Length 8x2M
Tube Length
12x1.5M
Exhause
VK3120-1H-01 x 2
VK332-1H-01 x 2
SOL.Y5
VX2330-03-1G
Exhause from
substance
Vacuum Pomp
Air control unit

AW30-02BDE-R
Air source
107
vacuum pump (with duct bracket)
Type : AG, BG, BH
(STA_B0620E ) 1
Vacuum
gauge
CDQ2B63-30DF9BVS
CDM2BZ25-75A-H7BS
Nozzle
Sealing
section
Cylinder (big)
Nozzle cylinder
Gas cock
Cylinder
(small)
LS.X1
LS.X4
Cylinder (big)
126E1-21
SOL.Y10
CQ2B32-25
LS.X3
LS.X2
Filter
CDQ2B63-30DF9BV
Circulation
switch valve
Air
regulator
Rapid exhaust
valve
Filter
SOL.Y4
SOL.Y11
PK0802-NC
SOL.Y3
SOL.Y2
SOL.Y1
Chuck valve
VK3120-1H-01 x 2
VK332-1H-01 x 2
Twinned
dry filter
Exhause
Duct
bracket
200E1
P
(Only BG,BH)
108
Relief
valve
SOL.Y5
VX2330-03-1G
A
R
Compressor
Vacuum Pump
O
I
14-4 Piping diagram for VG-602/402 series with vacuum pump (Air is
provided by the outside compressor) (with duct bracket)
Type (xx) : CG
Vacuum
gauge
CDQ2B63-30DF9BVS
CDM2BZ25-75A-H7BS
Nozzle
Sealing
section
Cylinder
(small)
Nozzle cylinder
Gas cock
Cylinder (big)
LS.X4
Cylinder (big)
LS.X1
126E1-21
SOL.Y10
CQ2B32-25
LS.X3
LS.X2
Filter
CDQ2B63-30DF9BVS
Circulation
switch valve
Air
regulator
Rapid exhaust
valve
Filter
SOL.Y4
SOL.Y3
SOL.Y2
O
I
SOL.Y1
VK3120-1H-01 x 2
VK332-1H-01 x 2
Duct bracket
Exhause
SOL.Y5
VX2330-03-1G
Vacuum Pomu
Air control unit

AW30-02BDE-R
Air source
109
15 Common problems and solutions

If you are experiencing problems with the machine, please refer to the chart below.
Carefully follow the directions in the operating instructions when replacing parts.
Please consult your dealer or Fuji Impulse if after referring to the chart, the problem cannot be resolved.
Please refer any questions regarding replacement of parts not listed in the operating instructions or adjustment
of such parts to your dealer or Fuji Impulse.
Items marked with an asterisk in the Solutions column refer to the fact that these problems should be
addressed by an electrician. If there are any problems, please contact your dealer or Fuji Impulse.
Warning
When replacing parts, be sure to unplug power cord from the wall outlet.
Service questions should be addressed to your local dealer.

Problems
Seal result is unsatisfactory.
Check
Solution
Heating element, teflon sheet or Wipe with clean cloth.

silicone rubber (white) is dusty.
Teflon sheet is damaged.
Slide the teflon sheet.
Silicone rubber is damaged.
Replace the silicone rubber (white).
Glass tape is damaged.
Replace the glass tape.
Heating temperature is too high.
Set the heating temperature to the

lowest in which sealing is possible.
Cooling temperature is too high.

Seal result is uneven at the right Silicone rubber is damaged.
and left sides.
Lower the cooling temperature.

Replace the silicone rubber (white).
Heating element is bent and risen in Electrode is damaged.

* Replace the electrode.
the center.
Silicone rubber (white) is exhausted Replace the silicone rubber (white).
and becomes uneven.
Heating element is burnt out easily.
Heating temperature is too high.
Set the heating temperature to the

lowest in which sealing is possible.
Cooling temperature is too high.
Lower the cooling temperature.
Glass tape is damaged.
Replace the glass tape.
Electrode is damaged.
Replace the electrode.
Although the heating lamp is on, Heating element is broken.

Replace the heating element.
heating element does not heat up.
Electrode does not touch with Scour the metal contact part of
heating element.
electrode and heating element with
a sand paper.
Electric wire / black (or blue) from * Attach the electric wire / black (or
the transformer is not connected
blue) to the electrode certainly.
with electrode.
SSR input lamp is off.
* Control unit may be damaged.
SSR input lamp is on.
* SSR may be damaged.
Replace the control unit.

Replace the SSR.
Heating continues (heating lamp SSR input lamp is off.
being on), and heating element and
teflon sheet are burnt out.
* Control unit may be damaged.

Replace the control unit.
Items marked with an asterisk in the Solutions a column refer to the fact that these problems
should be addressed by an electrician. If there are any problems, please contact your dealer or
Fuji Impulse.
110
Error message
Error message
Check
Poor heating
When the error is not solved with the

above-mentioned solution, please check
the lamp of the lower illustration 1, with
operating a machine. (Usually both two
lamps are turned on during heating.)
Solution
Is heating element broken?
Replace the heating element
Is electrode damaged, rustted,

or temperature sensor slipped,
or not installed?
If the temperature sensor is not

installed, it doesnt sense the
rising temperature and the
pressure lever return to the initial
state. Be sure to install the sensor
(Refer to P.90)
Are two red and daylight color

lamps turned off during
heating? (Ref. illustration 1)
If SSR-03 lamp is turned off,

control unit may be troubled.
If turned off
If SSR-03 lamp is turned on,SSR03 may be troubled.
Is SSR-03 lamp of the lower

illustration 2 turned on during
heating?
*Consult with your dealer or our

company.
Is only the red lamp turned off

during heating?
Microswitch may be troubled.

Replace it with reference to P.88
Illustration 1
Inside the frame cover
SSR-03
(xxx : 110 or 220)
Day light color lamp

(SSR-03)
(=output)
Illustration 2
Red lamp
(microswitch)
(=input)
Lamp for SSR-03
(=power)
Items marked with an asterisk *in the "Solutions" column refer to the fact that these problems
should be addressed by an electrician. If there are any problems, please contact your dealer or Fuji
Impulse.
111
Error message on display

Error message
Problems
Solution
1 lever-upper
Upper lever position cannot be

recognized
4 nozzle-back
Nozzle back position cannot be

recognized
2 lever
lever sponge position cannot be

recognized
3 lever-lower
Lower lever position cannot be

recognized
Error massge
Heat contorol
cant function!
Dont operate until
it removes a trouble
Check
Is SSR-03 lamp in the frame
cover turned on?
Adjustment or replacemrent of
cylinder sensor is necessary.
Please consult with your local
dealer
Solution
If SSR-03 lamp is turned on,
control unit may be troubled.
If SSR-03 lamp is turned off, SSR03 may be troubled.
*Consult with your dealer or our
company.
Over heating
If the temperature does not

reach to the setting within 3.5
seconds at heating, this
message is displayed.
112
Is the temperature sensor

slipped or not installed?
If the temperature sensor is not

installed exactly, it doesnt sense
the rising temperautre and the
pressure lever return to the initial
state. Be sure to install the sensor.
(Refer to P.90)
Transformer
*Transformer may be troubled.

Consult with your dealer or our
company.
Recommendation of the maintenance mode

The state of a machine is found by display in the
maintenance mode.
When the trouble occurs, we recommend to display the

maintenance mode.
The position of black marked X and Y told operator the
MAINTENANCE
X
Y
( means ON
means OFF)
trouble pattern.
Please tell your dealer or our company the result.
(Ref. "Select the maintenance mode" in page 43)
Each working of X0---, Y0--- is described in electric

diagrams (page 100 103) as IN (X) side and OUT (Y)
side.
X0 X1 X2 X3 X4 X5
Y0 Y1 Y2 Y3 Y4 Y5
113
16 Exploded view of major parts

16-1 Sealing section
Sponge holder (upper)

Pressure lever
Sponge rubber
Electrode
Sponge holder (lower)
16-2 Inside of the frame cover

Control unit
Vacuum gauge
Thermal relay
Circuit breaker
SSR-03
114
Fuse
16-3 Nozzle unit section

Vacuum / gas flushing nozzle
Air filter
Dry filter
Electromagnetic valve
for vacuum
Electromagnetic valve
for gas
16-4 Inside of the bottom plate
Auto transformer
Transformer
Nozzle cylinder
Cylinder (small)
Cylinder (big)
115
16-5 Inside of the body frame box
Frame cover
Body frame
Body frame box
Vacuum pump
(This illustration is DOP-80SA)
116
Air compressor
(This illustration is MP-40)
117
Y6575 JUL 2009. 3rd Edition

10-4 Combination of vacuum pump and air compressor
VG series sealer is named by the combination

of vacuum pump and air compressor.
ex.
Compressor : MP-40 (called A)
Vacuum pump : DOP-80 (called H)
602 series dual heating type
VG-602-AH-10D
Vacuum pump / 4 types
Air compressor / 3 types
H.
A.
DOP-80SA : Piston type

For standard
Pump weight : 7kg
D.
G-50SA : Oil rotation type
(small size pouch)
Pump weight : 11kg
E.
G-100S : Oilrotation type
(large size pouch)
Pump weight : 22kg
G.
DA-60S : Diaphragm type
For clean room
Pump weight : 12kg
96
MP-40 : Piston type

For standard
Weigh : 8kg
B.
DOA-P108-DB :
Diaphragm type
For clean room
Weigh : 7kg
C.
Air is provided by the out
side compressor
Suitable compressor
specification
0.75kw (80L/min) above
480KPa

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20092010FeasibilityandMarketResearchStudy

Four Star Farms hopyard, photo credit: r.wilson

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Commercial Feasibility of Local Hops

Courtesy: Vermont Farm Viability Enhancement Program

Average price paid to grower per dried pound

Return on Investment in Years

TOTAL CASH RECEIPTS

Total Fixed Expenses

TOTAL CASH EXPENSES

RECEIPTS MINUS EXPENSES

Plus CAPITAL CONTRIBUTIONS

Plus CAPITAL SALES

Less CAPITAL EXPENSE

Less DEBT SERVICE

NET RETAINED CASH EARNINGS (DEFICIT)

- Income Taxes (estimate at 33%)

NET AFTER CAPITAL RESERVE, FAMILY LIVING AND

Courtesy: Vermont Farm Viability Enhancement Program

Average price paid to grower per dried pound

Return on Investment in Years

TOTAL CASH RECEIPTS

TOTAL CASH EXPENSES

RECEIPTS MINUS EXPENSES

Plus CAPITAL CONTRIBUTIONS

Plus CAPITAL SALES

Less CAPITAL EXPENSE

Less DEBT SERVICE

NET RETAINED CASH EARNINGS (DEFICIT)

- Income Taxes (estimate at 33%)

Courtesy: Vermont Farm Viability Enhancement Program

Average price paid to grower per dried pound

Return on Investment in Years

TOTAL CASH RECEIPTS

TOTAL CASH EXPENSES

RECEIPTS MINUS EXPENSES

Plus CAPITAL CONTRIBUTIONS

Plus CAPITAL SALES

Less CAPITAL EXPENSE

Less DEBT SERVICE

NET RETAINED CASH EARNINGS (DEFICIT)

- Income Taxes (estimate at 33%)

Courtesy: Vermont Farm Viability Enhancement Program

Average price paid to grower per dried pound