Low-cost packshed structure design ideas

With the upcoming deadline for the Beginning Farmer Equipment and Infrastructure Grant program, we are publishing a series of articles about low cost equipment that can make farming more efficient on a small-scale. All of the equipment highlighted works well for farmers on rented land, as it can be easily moved to a new site. In this article, we highlight ideas for low-cost packsheds.

Packsheds are an essential part of food safe produce handling on the farm. Let’s begin by looking at common reasons for building a packshed and key features that must be included in any packshed design.

Why build a packshed?

Packsheds provide an accessible space for washing, packing and grading produce on vegetable farms.
Packsheds serve as a central space for storing harvest supplies like knives, rubber bands, produce bins and wax boxes.
Packsheds allow farmers to clean and pack vegetables in a food safe manner. This leads to better quality and longer lasting produce, which increases farm profitability.
With the right infrastructure and equipment, packsheds increase the efficiency of the washing and packing process.

Packshed features

Several key features must be considered in any food safe packshed design:

The structure: Your packshed should be as enclosed as possible to provide shade to workers and prevent contamination from birds and other animals. Your structure can be anything that provides cover.

Floor: You want to limit the amount of dirt and mud entering your wash and pack area whenever possible. Building a floor prevents mud from forming when the water used to wash produce falls to the ground. Floors also provide a stable area to place tables, shelves and equipment.

Tables: Your packshed must contain surfaces that can be used for packing vegetables into boxes. Whatever tables you use in your packshed must be water-resistant, easy to clean, and be able to hold a significant amount of weight.

Shelves: A packshed must have somewhere to safely store the supplies used to harvest and clean produce (e.g. rubber bands, harvest knives, and cleaning supplies). Without shelving, these items tend to end up on the floor, where they become dirty and create clutter that poses a physical hazard.

Wash and pack equipment: All packsheds must have equipment for safely washing and packing vegetables.

Hand washing: To ensure maximum food safety, create a space for workers to wash their hands near the entrance of the packshed. Stock this area with potable (drinkable) water, soap, paper towels, and garbage.

Water and electricity: You will need water access in your packshed. Mechanized supplies and equipment will also require electricity.

Low-cost, non-permanent packsheds

Packshed designs that do not involve permanent buildings or infrastructure (e.g. pouring a concrete floor) are useful for farms where you do not want to put up a permanent structure.

These designs are appropriate for any farmer, but they may be especially useful for farmers on rented land who lack the ability or reason to invest in permanent infrastructure.

The structure

The packshed structure provides a shaded area for washing and packing produce, and creates a controlled environment that is less likely to be contaminated by animals. Packing produce under a tree may provide shade, but creates a food safety risk, as trees are a gathering place for birds and other animals.

There are many types of non-permanent structures farmers can use for a packshed. Two of the most commonly used structures are market tents and carports.

Market tents

The least expensive non-permanent packshed structure is a market tent. Market tents can be used in a pinch, but they are discouraged for the following reasons:

Market tents are not built to resist wind and rain throughout the growing season. Even the best tents deteriorate quickly when set up for long periods of time. Some farmers work around this by putting up a tent while produce is being washed and packed, then taking the tent down. In this case, there is no secure area to store wash basins, wax boxes, and other equipment or supplies.

Most market tents are built for an 8x8 ft or 8x10 ft market stall - which is barely enough room for one person to wash and pack produce.

Carports

The recommended semi-permanent packshed structure is a carport with fabric covering. These structures are large (commonly 10x20 ft), stable, and relatively easy to construct and repair. Carports with steel roofs and temporary garages also make excellent packshed structures. However, these structures cost more and require a higher level of construction knowledge.

If you’re considering a carport structure, keep the following in mind:

Carports are available in a variety of shapes and sizes. Make sure the carport you choose can accommodate all of the equipment you plan to keep in your packshed while providing plenty of room for farm staff to maneuver.
If you plan to leave the structure up over winter, be sure it is rated to withstand significant snow load. Otherwise, plan to dismantle the structure for the winter and then rebuild it in the spring.
If you’re in a windy area make sure the structure has proper wind bracing and/or ground stakes. These items are often sold as accessories that can be used to make your structure more sturdy.

The floor

There are many different ways to build a non-permanent floor for a packshed. No matter what option you choose, start by laying down a thick commercial grade landscaping fabric. This will prevent weeds from growing and prevent dirt and mud from entering the area. Use a water-permeable landscaping fabric when possible. This way, excess water goes into the ground, instead of pooling on the floor.

One common way to build a floor for a non-permanent packshed is to use plastic pallets. For this design, be sure to use reinforced plastic pallets with a solid top. Other types of pallets easily break under the weight of human feet (even if they are rated to support much more weight, this rating is developed for weight that is more evenly distributed than the weight of a human). This type of pallet is very expensive when purchased new, but there are many options available from used pallet dealers like PalletOne, or on Craigslist and Facebook Marketplace. Pallets come in a number of shapes and sizes, but most are either 48’’x48’’ or 48’’x40’’. Plan to spend $20-$40 for a good-quality, used plastic pallet.

Another common way to build a floor in a non-permanent packshed is to lay a thick layer of gravel or stone over your landscape fabric. This allows water to drain through the gravel/stone while keeping the wash and pack area relatively dry, and free of soil and dirt.

Tables and shelves

Any packshed needs both a place to pack produce, and a place to store supplies. For packing produce, consider the following:

Folding, banquet-style tables are the simplest option. They are easy to clean, can be put up and taken down quickly, and generally support a sufficient amount of weight.

Stainless steel food prep tables are easy to clean (commonly purchased at restaurant auctions).

Roller tables are especially useful in a packshed, as they allow you to push a box of produce down a pack line instead of lifting and carrying it. Roller tables are expensive new, but are often available for less than $100 per 10ft section at auctions.

For storing supplies, wire racks work well and make good use of vertical space. Any wire rack you purchase should be NSF rated, meaning they are designed to be used in food safe areas. When deciding on the size of your wire rack, note the surface area of the shelves. Make sure they are large enough to store items like produce totes and wax boxes.