Monday, January 18, 2010

Maximizing wine grape water use: Paso Robles Case History

Maximizing wine grape water use

By Harry Cline, Farm Press Editorial Staff
Jan 15, 2010



Remnants of dryland almonds and prune production are interspersed with the oaks that dot the hills around Paso Robles, Calif.

Veteran Paso Robles, Calif., grape grower Jim Lockshaw, 82, has designed a new irrigation system and trellising for vines he hopes will do more with less water and labor.

For 82-year-old Jim Lockshaw, they are reminders of his early days of farming 30 years ago when he left the Los Angeles area for a more peaceful life in San Luis Obispo County, Calif. The 80 acres he bought included four acres of dryland Zinfandel grapes and the rest was made up of almonds. He made wine from the Zinfandel grapes and later established Twin Hills Winery.

It was the seventh winery established in the Paso Robles area. Today there are more than 200 in California’s newest premium wine grape growing area. He sold the winery 15 years ago, and bought more land, where he is growing grapes with his son Curtis. Curtis, who moved to the area 11 years ago, farms 40 acres of Zinfandel, Cabernet and Syrah. Their vineyard is called Oak Flat Vineyard.

Lockshaw has witnessed the modern day wine grape transformation that first began east of town three decades ago where there is an underground aquifer feeding large vineyard blocks. West of town where Lockshaw and his son Curtis farm, water has always been scarce, and the vineyards are much smaller because of the limited water supply.

VETERAN PASO Robles, Calif., grape grower Jim Lockshaw, 82, has designed a new irrigation system and trellising for vines he hopes will do more with less water and labor.

There remain many dryland vineyards nearby, but drip irrigation has made this Western area explode into a premium wine grape growing locale.

However, even with drip the water supply is tenuous. Curtis begins the season pumping from about 100 feet to feed his vines the necessary 8 gallons per week from May through October to produce 3 tons per acre. By October, he may be pumping from 200 feet or more. Hopefully, it will recharge over the winter, but the last three years of drought in California have taken their toll on the water supplies from wells.

Curtis and his father have been able to manage with their limited supply. Others are not so fortunate. One winery the Lockshaws sell grapes to also farms 80 acres and the owner is forced to truck in water to produce a crop.

Drip irrigation is by far the most efficient way to get water to the vines and has been a key reason for the Paso Robles wine grape explosion. However, the elder Lockshaw has long thought there must be a better way.

“Unfortunately, even with conventional drip much of the water evaporates or is blown away and fertilizers that do not percolate into the subsoil support unwanted weed growth and can run off,” he said.
Lockshaw is experimenting with changing the way to drip irrigate with a half-acre of newly planted Grenache wine grapes irrigated with a system that delivers water beneath the soil directly to the plant roots.

“So far it seems to work well,” he says.

The vines in Lockshaw’s young experimental vineyard used only 3 gallons per week per vine this last year, compared to the 8 gallons for Curtis’ conventional drip irrigated vineyard.

“The vines are still young, and we need to see how this will work a few years out. However, I am encouraged,” said the elder Lockshaw.

The irrigation system starts with augering a hole 12 inches in diameter and 36 inches deep for each vine. A grape stake is positioned into the hole with a half-inch PVC pipe taped to the stake. The PVC pipe is inserted 24 inches into the ground next to the vine and extends 12 inches above ground. The hole is filled half full with pea gravel and the remainder of the hole is filled with soil. “We added a growth pellet to each hole when we planted,” he noted.

The half-inch PVC pipe is capped initially when the dripper hose is inserted directly to the plant grow tube, and the tubing is then connected to an emitter tapped into the main line suspended from the grape stake.

“When the new plant shows enough vigor, we punch a hole through the half-inch cap and transfer the dripper hose into the top of the pipe. This deep watering forces the root system away from the surface,” he said. “The first crop was excellent quality and used less than half the water we normally would with surface drip irrigation,” he said.

With no water on the surface of the vine rows, there were no weeds during the season. Winter rains generate weeds, however, and those are cleaned out.

With drip irrigation, you have to make sure each dripper is functioning properly. “It has been quite simple to pull the dripper hose out of the PVC cap to check that the drippers are functioning,” he said.

“We plan on adding nutrients through the drip system as needed.

Because the nutrients are not supporting surface weeds it should require proportionally less,” he said.

The pea gravel is the key to the underground water system. It allows the water to be dispersed into the root zone of the vine.

Lockshaw also used the Grenache vineyard to experiment with a trellising system. The vine rows are only 6 feet wide with 4 feet between vines compared to the family’s commercial vineyard which is planted 10-by-8 feet. There is only one wire in the experimental vineyard to support the cordon positioned atop each large, round grapestake. The cordon is 5 feet high compared to the 3 to 4 feet for Curtis Lockshaw’s VSP trellised vineyard.

“The cordon is probably about 6 inches too high. The tall cordon is to allow pruners and pickers to work without bending over. The idea is to put the work area about shoulder high,” he said.

“Paso Robles has proven to be a great area for growing premium wine grapes with irrigation. But we need water ... Dad’s idea is to do more with less water,” said Curtis.


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Reprinted with permission, from Western Farm Press, Jan 15, 2010

Sunday, January 17, 2010

Cork Producer ACI Conserves Water in Production, Cuts Water Usage 17%


ACI Cork USA Announces Eco Progress in Producing Natural Cork Wine Stoppers: Uses 17% Less Water in its Portuguese Cork Factories, Fabrication Systems

Fairfield, CA, USA -- Water usage reduction of 17% in two years makes cork wine stoppers from ACI CORK USA a closure alternative that is more environmentally friendly than any other option available in the wine industry today. Statistics recently released by ACI CORK USA show that the production facilities of parent company Àlvaro Coelho & Irmãos, S.A., in Portugal have greatly reduced water used per kilo of corks produced. (See chart below)

Vineyard managers and wineries know the value and importance of water conservation, re-use and recycling. Water rights issues and climate change has resulted in concerns about water availability and quality all through the winemaking system, and now ACI CORK reports significant reduction in their water consumption in cork processing.

The sealed autoclave process, NBS, used by ACI in its cork processing plants not only assures high quality clean cork, but also is more conservative of water than other types of cork processing systems. ACI recycles all water from its cork processing and cork finishing plants.

Àlvaro Coelho & Irmãos, S.A., has achieved its 17% water reduction per kilo of corks produced in several ways: they have optimized the amount of water used in cork production (sorting, washing and other production processes), and tightened up the supply system to assure water conservation practices all through the company including both industrial and domestic wastewaters.

The sustainable and ecological benefits of ACI’s cork as natural wine stoppers are already well known. Portugal accounts for one-third of the world’s cork oak forest area, and Portuguese foresters have added 3.3% more acreage in the past 10 years, to 736,700 hectares (1,820,400 acres) under cultivation.

Cork oak trees “fix” huge amounts of the greenhouse gas carbon dioxide. Calculated on a basis of tons of natural cork stoppers, 2 tons of CO₂ is fixed per one ton of cork stoppers produced. An average of 357,145 stoppers is produced per 1.3 acres of dense cork oak forest. The regenerating bark of the cork oak is harvested under stringent guidelines at the rate of only once every 9 years.

In the water conservation arena, ACI augments its progress in water consumption reduction by going one step further: treating wastewater in its own water treatment plant so that water can be forwarded back to the water supply company pre-cleansed for final treatment.

The ACI treatment plant technology is based on biological treatment with a macrophytes layer. Macrophytest are aquatic plants that are introduced into sealed treatment tanks, and they produce oxygen and remove contaminants. In the treatment process, wastewaters enter a septic tank where the pH is adjusted, and the water is filtered in a way that suspended solids are retained. This filtered water proceeds through a series of tanks with machrophytes where bioload and other contaminants are eliminated. This water then goes back to the water supply company for final treatment. After treatment in the regional facility, the water from ACI’s cork wine stopper production facilities can be totally re-used.


ACI has achieved 17% water reduction per kilo of corks produced





For more information, contact Armando Andrade, General ManagerACI CORK USA2870 Cordelia Road, Suite 150Fairfield, CA 94534 USA sales@acicorkusa.com or Henrique Figueiredo, Sales Director, Àlvaro Coelho & Irmãos, S.A., AP. 56, Zona Industrial de Prime, 4536-902 Mozelos - VFR Portugal, henriquefigueiredo@acoelhoirmaos.com

Saturday, November 14, 2009

$45 Winery Sustainability and Design Education Series Online from VT

"In early 2008 the Virginia Tech wine department organized a very successful Winery Sustainability and Design program covering many winery sustainability issues. Because of the success of this event and the importance of the subject, Dr. Bruce Zoecklein posted an Adobe Presenter version of this Online. The subjects included in these audio and Power Point slide presentations are as follows:

 Sustainability in Winery Design
 Sustainable Winery Architecture
 Why Solar, Why Now
 Gravity Flow Design, Principles and Practices
 Cellars, Caves and Earth-Sheltered Design
 Winery Construction and Sustainable Building Materials

Each presentation is approximately 45 minutes long. Topics are discussed by some of the most respected winery architects, engineers, and winery planners from California and the Pacific Northwest.

This password-protected program is available for a donation of $45 to the Enology-Grape Chemistry Group at Virginia Tech. These funds will be used to support graduate student education. Check it out at:
http://www.vtwines.info/ "

This info from Iowa State's Michael L White. who produces a fantastic bi-weekly newsletter called Wine-Grower-News: issue #104 October 9, 2009

Monday, October 19, 2009

Keeping up: Good Info on the State of Water Supplies in California


Did you know that Ag Alert, the publication of the California Farm Bureau, has an ongoing series of articles that provides coverage on the state of water supplies in California?
It is very comprehensive, up-to-date, and free. Go to http://www.cfbf.com/agalert/watercrisis.cfm


September 9, 2009

Governor says state is short of both water and patience
Commentary: Cal Poly water expert offers an Rx for the delta

Pretty impressive; if California water issues affect you, you might want to bookmark this site:

Electronics Monitor Vines' Water Needs in Boeger Winery, El Dorado


From time to time, representatives of winery associations will give a glimmer as to the status of that region's water issues. Jolaine Collins works with the El Dorado Winery Association, and her quick report is that several El Dorado wineries are proactive with sustainable farming practices, including water conservation.

"In the Placerville area, Boeger Winery, the region’s largest grape grower and winery, works with the El Dorado Irrigation district on using electronic probes to monitor the vines’ water needs," Jolaine noted. "Greg Boeger told me that many of the region's wineries employ this irrigation management system to monitor and predict their vineyards' water needs on a weekly basis, and mentioned that both Boeger and neighboring Madrona Vineyards have specific vineyards that sometimes require as little as one application of water per year. "

In the south part of El Dorado County, the Fair Play wine region is faced with an even tighter water supply than its neighbors to the north, she said. "Without water storage facilities, Fair Play’s local water agency depends on Mother Nature for the south county's water allotment."

The El Dorado Winery Association includes 29 wineries, the majority of them family owned. Growing grapes in hundreds of microclimates from 1,200 to 3,500 feet, the county contains more than 2,000 acres of vines, and is home to approximately 50 wineries. El Dorado was designated an American Viticultural Area (AVA) in 1983.

Reclamation Ponds enable Gundlach Bundschu to Recycle 70% of Winery Water Used


What an amazing thing...recycling 70% of winery water used. This is the performance achieved by Gundlach Bundschu’s water reclamation ponds. The system is a series of ponds and wetlands that takes all of the process water used in the winery and naturally filters it to be reused to irrigate the winery. They've achieved this high recycling performance quite easily with their system....of course some is lost to evaporation. The system is 100% solar powered by the first array of floating solar panels in Sonoma County, only the second of its kind in the world.

(Photo: Main Irrigation Pond as seen from Winery Courtyard)


Thanks to Gundlach Bundschu for providing this in-depth explanation of how the water is processed:

"As winery process is generated from harvest and winery operations the process water is collected in drains throughout the winery. As the water flows into the drains the solids are first separated using stainless steel screens. These screens are cleaned routinely to eliminate as many solids before they reach a large sump pump. This pump will pump the process water to a solids separator which will then remove any large solids such as stems, skins, wood, rocks that may have made its way through the initial screening process.

The solids separator has a screen/drum that rotates like a wheel picking up any solids mentioned above. On the end of the screen/drum is what is called a knife, basically it is a scraper arm that will wipe the solids off the drum into a bin below which will then be composted.

The water that flows through the solids separator flows into two concrete holding tanks for settling of suspended solids. As the water flows into the first tank, the fine particles fall out to the bottom of the tank as the water gravity-flows out of the top of the tank to the second tank. The second tank will do the same thing just further clarifying the water before it gravity floes the rest of the way to the treatment ponds. No electricity is used to pump the water for its 1/8 mile trip to the process ponds.

As it enters the first pond it comes in from under the water level. This allows the water to bubble up to the top. Due to the high organic content in the water, oxygen is needed to allow microorganisms to naturally breakdown the remaining suspended solids that reach pond 1. Therefore we introduce oxygen into the water with fine bubble diffusers. The 6 diffusers are located 4 feet from the bottom of the pond so that the fine bubbles can transfer the oxygen efficiently into the water feeding the organisms that eat the remaining organic matter. Most systems have what we call splash aeration. These systems are not efficient due to the fact that most of the oxygen escapes back into the atmosphere instead of transferring the oxygen to the water.

In this first pond we have a system that monitors the dissolved oxygen (DO) as well as the pH. The ideal level for DO is 2 and the ideal level for PH is 7. You may ask why these numbers are so important? If the pond drops below 2 on the DO, the organisms will not have enough oxygen to survive therefore they die. If the pH drops below 7 the water will be to acidic for the organisms to survive therefore they die. This is why it is so important to monitor your system. The monitoring system calculates readings every 10 minutes from 2 probes in the middle of the pond which sends the info back to a control panel which in turn determines the run time needed to keep the DO and pH at optimal conditions. This system is so smart that it can even run on off peak hours, saving electricity.

From the first pond the water gravity-flows into a sump that pumps the water to our wetlands area which has a 3% slope. The water is further filtered through the pea gravel on the bottom of the pond. The plants in the pond are all natural wetland plants that aid in further filtering. Ducks love this little sanctuary as well as Killdeer. Once the water naturally makes its way to the other end of the wetlands filtering its way along, it goes into another sump which then pumps the filtered water into pond 2.Pond 2 is a storage pond for the filtered water. Each of the process ponds are 13ft deep and hold 510,000 gals. The water from pond 2 is pumped back to the main reservoir located next the winery to be used once again in the vineyard. This way, we recycle 70% of our winery waste water – the other 30% is lost to evaporation off the ponds – significantly reducing the water we draw from our wells.

The system is powered by 162 Sharp solar panels on pontoons that float on pond 1. This 30kW Floatovoltaic system provides 100% of the power needed to run the water reclamation system, and is the second floating array of its kind in the world. It was designed by Thompson Technology Industries (TTI) and installed by SPG Solar, Inc. of Novato."


(Photo: Solar panels being installed on pond at Gundlach Bundschu)