Managing A Poor Harvest In The Best Possible Way

The only post-harvest treatment required for the longwell ventilated conditions and using air at about 30°C,
storage of bulb onions is a thorough curing of the bulbs.60-75% rh and 150 m³.h-1.m-3 is generally
Curing is a drying process intended to dry off therecommended for mechanical drying of onions.
necks and outer scale leaves of the bulbs to prevent2.4    Cleaning
the loss of moisture and the attack by decay duringFreedom from any impurity, which may materially alter
storage. The essentials for curing are heat and goodthe appearance or eating quality, is essential. Soil and
ventilation, preferably with low humidity. This dries outother foreign materials must be removed and badly
the neck and the two or three outer layers of the bulb.affected produce must be discarded. Cleaning may be
The outermost layer, which may be contaminated withcarried out using air or by manually removing
soil, usually falls away easily when the bulbs are cured,unwanted materials on the bulb surface.
exposing the dry under-layer, which should have anCare should be taken to avoid physical injury on the
attractive appearance. Onions are considered curedbulb during these operations.
when neck is tight and the outerscales are dried until2.5    Packaging
they rustle. This condition is reached when onions haveGeneral Information
lost 3 to 5% of their weight.Good packaging for onions must meet the following
If onions cannot be dried in the field, they can becriteria: (a) strong enough to retain the required weight
collected in trays, which are then stacked in a warm,of onions under the conditions of transport and
covered area with good ventilation.storage, (b) allow sufficient ventilation for the air around
In cool, damp climates, onions in bulk ventilated storesthe bulbs to maintain relative humidity in the required
are dried with artificial heat blown through the bulk at arange, and (c) in many circumstances, provide a
duct temperature of 30 degrees Celsius.means of displaying legally required and commercially
Onions can also be cured by tying the tops of thenecessary information (Brice et al., 1999).
bulbs in bunches and hanging them on a horizontal poleThere are many traditional methods of holding onions
in a well-ventilated shades. Curing in shade improvesfor transportation and/or storage that do not fit into
bulb colour and reduces losses significantly duringconventional packaging classifications. These include
storage'string of onions', shelves and loose bulk In 'string of
Gradingonions' packing, the bulbs are tied together by means
Onions after curing are graded manually before theyof their tops to produce a bunch of bulbs is also a
go in to storage or for marketing. The thick neck,form of packaging. This is suitable for transporting
bolted, doubles, injured and decayed bulbs are pickedsmall quantity of crop, and during storage, the bunches
out so also misshapen small bulbs. Sorting and gradingare hung from the roof or from special racks. Shelves
is done after storage also to fetch better price. Thefor onion handling and storage are made from either
outer dry scales usually rub off during the gradingwooden slats or metal mesh on a wooden or metal
process, giving the onions a better appearance forframe, and are usually fixed in position with the bulbs
market. It has been experienced that if storage isloaded and unloaded in the store.
arranged after proper sorting and grading losses inVentilation (natural or forced) is usually achieved by
storage are reduced.passing air over the shelves. To achieve adequate
For local market the onions are graded based on theiraeration of the bulbs, the depth of bulbs on the shelves
size.should be limited to 10 cm.
Extra large onion (>6 cm dia.)Onions are also stored loose bulk (instead of
Medium (4-6 cm dia.)containers) by heaping the bulbs directly on the floor or
Small (2-4 cm dia.)elevated platform. Because they are not restrained,
The extra large onions have great demand andthe bulbs roll during store loading to completely fill the
fetches very good price.storage space. Bulk storage permits maximum
General Characteristicsutilisation of store space, and uniform aeration is easier
The bulbs shall:to achieve than in stacks of bags or other rigid
•    be reasonably uniform in shape, size colourpackaging.
and pungency of the variety /typeHowever, where bulk storage is to implemented, the
•    be mature, solid in feel, reasonably firm withretaining walls must be strengthened when storing
tough clinging skins.larger quantities of bulbs, and arrangements need to be
•    be throughout cured and dried.made for rebagging before subsequent marketing. It is
•    be free from dust and other foreign material.also difficult to inspect bulbs regularly under these
•    be free from defective, diseased, decayedstorage conditions. Loose bulk handling of onion is most
and damaged bulbs caused by seed stems, topssuitable for large-scale operations where forced
•    oots, moisture, dry sun scald burn, sprouting,ventilation can be provided during long-term storage.
mechanical or other injuries and staining.Soft cultivars (which are also generally sweet) 'Vidalia
•    be free from moulds, soft rot and insectSweets' should not be stored in loose bulk because of
attack.their high susceptibility to compression and impact
•    % of seed stem or bolted bulbs shall notdamage.
exceed 20% in Nasik kharif onions.Onions can be packaged and stored in a variety of
Bangalore and Krishnapuram onions will be free fromcontainers such as boxes, cartons, bags, bulk bins,
bottle necks or doubles.pre-packs, plastic film bags, and stretch-wrapped trays.
Grade designations and definitions of quality for exportPackages typically contain 25 kg and above, especially
of onions:for transporting crop from field to store and/or during
Different size but not below 15storage. The same 25 kg bags or smaller bags may
1. Tolerance for size in big onions: For accidental errorsbe used from store to market place. Decision on which
in sizing, not more than 5 % by weight of the bulbs intype of packaging to use depends on crop size, length
any lot may be of next lower grade than the minimumof storage and marketing requirements. A problem
diameter prescribed in Nasik, Saurashtra, Bellary orwith packaging onions in boxes, net bags and bulk bins
Poona onions. In case of Podisu, this error in sizing notis that if they are too large, and airflow pattern tends
more than 10 % by weight. In this case, smallest onionto be around rather than through them. Under this
in bunch would be taken for measuring the diameter.condition, the respiration heat of the bulb results in a
2. Defective, diseased and damaged shall meanwarm, humid environment in the centre of the
malformed bulbs and the bulbs internally or externallypackage, which can result in decay or sprouting. To
damaged, diseased or discoloured material affectingavoid these problems in large stores, the capital
the quality. The decayed onions shall not exceed 2% ininvestment in packaging may be quite substantial.
any lot.Onion Bags
General: The grade shall be allowed to be packed onlySacks and nets used for onion packaging fall into three
against irrevocable letter of credit.groups: (i) general-purpose jute sacks, as used for
# NS grade: This is not a grade in its strict sense butmany agricultural commodities, (ii) open-weave sacks
has been provided for the onions not covered underof sisal-like fibre, (iii) open-mesh nets, normally of plastic
regular grade. Onions under this grade shall bematerials and (iv) big bags, used alternatively to crates,
exported only against a specific order from foreigncontaining up to 1000 kg . Jute sacks are readily
buyer inducting the quality.available in most developing countries, but their
Packagingdisadvantages include: (i) generally too large - may
Packing should be small for easy handling during transitcontain 100 kg onions, hence difficult to handle and an
and may vary according to market demand. Onionsincreased risk of mechanical damage; (ii) bulbs are not
are packed in jute (hessian) bags for transporting tovisible through the fabric, and it is difficult to monitor
yard or brought as loose. For safe handling, 40 kgcondition during storage; (iii) there is some resistance to
open mesh jute bags having 200-300 g weight shouldairflow if they are used in an aerated store; (iv) difficult
be used in domestic market. For export, common bigto label effectively; and (v) recycled sacks may
onions are packed in 5-25 kg size open mesh juteencourage spread of post harvest diseases.
bags.Sisal sacks are made from sisal-like hard fibres and
Bangalore Rose and multiplier onions are packed forhave an open weave, with thick threads spaced
export in 14-15 kg wooden baskets. Nylon net bags,between about 10 and 15 cm apart. The rough nature
when used for packing have resulted in less storageof the fibre provides a sufficiently stable weave.
loss because of good ventilation.These sacks are similar to jute sacks, but will allow
Handlinglimited visibility of the onions and impedance to airflow
Bulbs intended for storage must be free from cuts andis less.
handled with extreme care. Onions should not beOpen-mesh nets are the most widely used package
dropped on to non-resilient surface from more than 6for onions, and they are normally red or orange in
feet height. If onions are to be stacked after packing incolour. The slippery nature of plastics can result in the
store or trucks, the better height is 2-2.5 metres.movement of the threads allowing large holes to open
Losses due to rot is reported to be more if onions areup. To overcome this problem, alternative nets are
stored in gunny bags than in loose or wooden crates.industrially produced to give fully stable mesh and
Storagestronger bag. The principal techniques include: (i) using
Proper storage of bulbs is necessary both forextruded net from high-density PVC, (ii) knitted
consumption and also for seed production. Onions(warp-knitted) and asymmetric construction, and (iii)
should not be stored unless adequately dried either inspecial weave in which weft threads are double, and
the field or by artificial means. It is necessary to dry thetwisted. They are also slowly degraded by sunlight,
neck tissue and outer scales until they rustle whenand should not be left outdoors for long period before
handled otherwise the bulbs will rot in storage.use. In comparison with the other types of bags, they
Sprouting in onion is controlled by temperature. Theoffer several advantages, including: (i) light weight, small
temperature between 10-25°C increases sprouting.bulk when empty, (ii) usually available in 12.5 and 25 kg
Rooting is influenced by relative humidity (RH).sizes, (iii) fairly good visibility of bulbs, (iv) excellent
More the relative humidity, more is rooting. Weight lossventilation, (v) hygienic, (vi) easy closing (draw-string
is more when temperature is above 35°C. Undertypes only), (vii) and crop brand and marketing
ambient conditions the onions are stored at ainformation may be printed around the middle of the
temperature of 30-35° C with RH of 65-70%. In coldbag for easy identification.
storage, temperature is maintained at 0-2°C while theRigid Packages
RH is kept at 60-75%.A range of rigid containers is used to package onions
Sprouting is checked effectively if Maleic Hydrazide atfor transportation, marketing, and/or storage (Opara
2500 ppm is sprayed at 75-90 days after transplanting.and Geyer, 1999). The principal rigid containers are
Effect is, however, more pronounced in kharif seasontrays (10-15 kg of onions each), boxes (up to 25 kg),
than in rabi season. The storage rots could beand bulk bins (up to 1000 kg). These types of
checked if proper cleanliness is maintained in store andpackaging enable segregation of onions into different
crop is sprayed with 0.1% Carbendazim after 90 dayscultivars or sources. Choice of packaging material is
of transplanting and just before harvest. In India, theimportant as wooden bins, for example, are liable to
farmers practice different storage methods. Thetermite attack, and weathering during off-season. Rigid
onions are bulk stored in special houses with thatchedcontainers are also expensive, need regular
roof and side walls are made up with bamboo sticksmaintenance and a forklift is required for handling larger
or wire mesh for good air circulation. In North India, thecontainers. Where rigid containers are used for onion
sides are also covered with gunny cloth. Onions arestorage, building design is simpler than that for
stored in these sheds by spreading them on dry andlarge-scale loose bulk storage as reinforcement of
damp proof floor or racks. Periodical turning of bulbs orretaining walls are not required to support the bulbs.
removal of rotten, damaged and sprouted bulbs shouldHandling damage of bulbs during filling and emptying
be done. Well-ventilated improved storage structurescan be high, but damage is reduced during store
with racks or tiers having two or three layers of bulbsloading and unloading operations in comparison with
would be desirable for proper storage.loose bulk handling and storage.
The salient features of improved storage structuresStacking of containers must be carried out with care
are as belowand to ensure that the ventilation air is forced through
•    Construction of storage godown on raisedthe containers of bulbs and not around them. One of
platform helps in reduction of moisture and dampnessthe main advantages of rigid containers is that they
•    Use of Mangalore tiles roof or other suitablefacilitate regular inspection of produce, and when
material prevents built up of high temperature inside.problems occur with the stack, the area affected is
•    Increased centre height and more slope isoften limited to a few trays, boxes or bins which may
better for air circulation and preventing humidbe more easily isolated and removed than in loose bulk
microclimate inside godown.handling system.
•    Bottom ventilation provides free and fasterOnion Pre-packs
air circulation to avoid formation of hot and humidOnions are commonly sold in retail outlets in pre-packs
pockets between the onion layers.with a capacity of 0.5-1.5 kg. Pre-packing offers the
•    Avoid direct sunlight on onion bulbs to reducefollowing advantages over single bulbs in heaps or
sunscald, fading of colour and quality deterioration.bags: (i) price can be attached to produce, (ii) the
•    Restriction on width of each stack to 60-70collation of a number of pieces into one unit of sale
cm for cool humid weather, 75-90 cm for mild andmay promote sale of a larger quantity than would be
humid weather and 90-120 cm for mild and drypurchased otherwise, (iii) provides a clean odourless
weather conditionsunit for the customer to handle, and (iv) reduces time
•    Restriction of stacking height to 100 cm forspent at the check-out. The use of weight/price
small and multiplier onion and hot weather and 120 cmlabelling machines and bar-coding has reduced the
for mild weather and for big onion to avoid pressureneed to pack to fixed nominal weights. During
bruising.preparation for retail, the quantity of produce is
•    Cubicles should be made instead ofmeasured by hand or machine and filled into the pack.
continuous stack leaving sufficient space for ventilationThen the actual weight and price and/or bar-code are
from all the sides.automatically calculated and printed on a label, which is
One cubic metre area of store accommodates aboutattached to the package. This mechanised weighing
750 kg onions.and labelling system assists the packer in accurate
Transportrecord keeping and avoids losses due to inaccurate
Onion stocks are transported in bullock carts, tractorpack weights. The three main types of onion
trolleys and trucks as also railway wagons are usedpre-packs are nets, plastic film bags, and
for longer distance movement within the country.stretch-wrapped trays
Onions are transported in ventilated ships as well as2.6    Bulk Storage
sailing vessels / motorboats for export to Gulf andGeneral Requirements
South-East Asian countries. It is also shipped in 3.5mThe objectives of onion storage are to extend the
containers or 7m containers by loading on ships.period of availability of crop, maintain optimum bulb
............................................................................................................quality and minimise losses from physical, physiological,
2.1    Pre-harvest Operationsand pathological agents. Bulbs selected for storage
The condition of onion leaves is a good indicator of theshould be firm and the neck dry and thin. Discard
maturity and general state of the bulb. Bulb onionsthick-necked bulbs because they are most likely to
which are to be stored should be allowed to maturehave high moisture content than optimum for storage,
fully before harvest and this occurs when the leavesand therefore would have short storage life. Skin
bend just above the top of the bulb and fall over. As acolour should be typical of the cultivar. Microbial
practical guide, farmers should conduct sample countsinfections such as Aspergillus niger occur during
on the number of bulbs, which have fallen over in aproduction of onions but these will only develop on the
field; and when the percentage of bulbs, which havebulbs during storage where the storage environment is
fallen over, reaches about 70-80% then the entire cropconducive for their growth. Prior to storage, crop must
should be harvested. Harvesting could commencebe cleaned and graded, and all damaged or diseased
earlier when 50-80% of the tops have gone over,bulbs removed.
before it is possible to see split skins exposing onionCareful harvest and pre-storage treatments with
flesh Storage losses at optimum maturity are normallyminimal mechanical loads are important to achieve a
lower than those harvested before the tops collapse.long storage period. Both store room temperature,
Bulbs generally mature within 100-140 days fromrelative humidity, and atmospheric composition affect
sowing, depending on the cultivar and the weather.the length of storage that can be achieved. Several
Spring onions mature for harvesting after 35-45 daystechnology options are available for bulk storage of
from sowing. Harvested crop should be allowed to dryonions, including low-temperate storage,
or cure and ripen in the sun for several days afterhigh-temperature storage, 'direct harvest' storage and
lifting. Onions can yield up to 5 t.ha-1 under goodthe use of controlled atmosphere (CA) stores. The
growing and management conditions.recommended storage conditions under these
2.2    Harvesting & Transportsystems are summarised below.
Manual harvesting is the most common practice inStorage at Low Temperature
most developing countries. This is normally carried outFor successful low temperature storage, good
by levering the bulbs with a fork to loosen them andventilation and a low level humidity in the range of
pulling the tops by hand. In developed countries,70-75% is essential. To maintain good quality crop, the
especially in large scale farms, mechanical harvesting isperiod of storage varies but may be up to 200 days.
commonly used. The harvesting techniques adoptedFor maximum storage period and minimum losses
are influenced by weather condition at harvest time. Inbulbs should be fully mature at harvest, and dried until
areas where warm, dry weather occurs reliably, thethe 'neck' of the bulb is tight. For large-scale
curing and bagging of the crop can be done in the fieldcommercial storage, onions are usually stored under
(two phase harvesting). In wetter, temperate regions,refrigeration and the most commonly recommended
mechanical harvesting and artificial heating andconditions are 0°C with 70-75% rh. Regular ventilation
ventilation for drying are essential for reliable productionand monitoring of both temperature and relative
of high quality bulbs on a large scale.humidity in the store are necessary to avoid significant
The following steps are followed during two-phasefluctuations in environmental conditions. During the first
harvesting of onions: (a) mowing the leaves (iffew days of storage the fans should provide an
necessary); (b) stubbing, undercutting and sieving theadequate airflow, to remove water in the outer skins
onions to remove stones and clods; (c) roll the soil inand to dry bruises. High air speed is needed for a
the row to get a plane surface; (d) drying the bulbsperiod of up to 1 week, until the skin of the upper onion
(windrowing) 8 to 10 days in the field; (e) turning thelayers in the bulk rustles. Excessive humidity in-store will
bulbs 1 to 2 times; (f) harvesting, sieving andlead to the development of roots and promote rotting
hand-grading, overloading into a trailer or in crates; andwhile higher temperatures will result in sprouting and
(g) transport. For one phase harvesting usuallypromote development of pathological disorders such
commercial potato harvesters have been adapted.as Botrytis rots (Thompson, 1982) Bulbs freeze below
After mowing the leaves the crop is immediately-3°C and a range of storage temperatures and
harvested, sieved, hand graded and loaded onto therelative humidities have been recommended for safe
trailer. Because of the additional operations involved,storage of onions (Table 5).  Spring (green) onions
labour costs for two-phase harvesting are about 30 tostore best at about 0°C and very high humidity
100 % higher than for one phase harvesting. The main(95%) (Table 6). The maximum length of storage
disadvantage of one-phase harvesting is the highunder these conditions varies from just a few days to
energy consumption required for mechanical drying.about 3 weeks.
Using combine harvesting, the standardised workingVentilation must be carefully applied inside the store to
hours has been calculated to be 2.7 to 2.9 hr.ha-1 forachieve the required temperature and humidity levels
stubbing, 2.4 to 2.6 hr.ha-1 for turning and 8.9 to 11without inducing condensation of water on the surface.
hr.ha-1 (KTBL, 1993).Onion Storage at High-temperature
Harvested bulbs are placed in containers (basket, bins)Onions can be stored at high temperatures of over
or tied into bunches and placed directly on the floor of25°C at a range of relative humidities (75-85%)
a trailer for transport. These trailers can be pulled bywhich is necessary for minimising water loss.
an animals (such as donkey) or mechanical transportStorage at temperatures of 25-30°C has been
such as a tractor. Both packaging and transportshown to reduce sprouting and root growth compared
systems must be selected to ensure minimum handlingto low-temperature storage (10-20°C). However,
damage to produce. Hard surfaces should beweight loss, desiccation of bulbs, and rots occurred at
cushioned with leaves, foam or other appropriatehigh temperatures, making the system uneconomic for
force decelerators.long periods of storage that is required for successful
2.3    Curing & Dryingonion marketing (Thompson et al., 1972; Stow, 1975). In
Both curing and drying remove excess moisture fromtropical climates, high-temperature storage of onions
the outer layers of the bulb prior to storage. The driedcan be achieved under both ambient and heated
skin provides a surface barrier to water loss andstorage conditions. Under these conditions, ventilation
microbial infection, thereby preserving the main ediblemust be carefully applied inside the store to achieve
tissue in a fresh state. Drying also reduces shrinkagethe required temperature and humidity levels.
during subsequent handling, reduces the occurrence of'Direct Harvest' Storage
sprouting, and allows the crop to ripen before freshThe need to cure onions can pose considerable
consumption or long-term storage (Opara and Geyer,challenges in situations where the climatic condition is
1999). This process of dehydration is sometimes calledunpredictable during the harvest period. To overcome
'curing', but the use of the word 'curing' for onion dryingthese problems, the 'direct harvest system' has been
is rather inaccurate since no cell regeneration ordeveloped and used extensively, particularly by
wound healing occurs as in other root crops such asgrowers in the UK, since the early 1980s. The bulbs are
yam and cassava. Drying reduces bulb weight andharvested while green, topped, loaded into store, dried
since they are sold mostly on a weight basis, achievingand cured using well controlled ventilation system, and
the desired level of dehydration is critical. Weightthereafter held in long-term low-temperature storage
losses of 3-5% are normal under ambient dryingas required (Table 7). During stage I, removal of
conditions and up to 10 % with artificial drying.excessive surface moisture is achieved at high airflow
In traditional small-scale operations, onion drying isrates, ignoring the rh of the air. Stage II is completed
carried out in the field in a process commonly calledwhen the skins have been cured on the bulb.
'windrowing'. It involves harvesting the mature bulbs andAdequate control of the storage condition at the
laying them on their sides (in windrows) on the surfacevarious stages is critical to the success of this storage
of the soil to dry for 1 or 2 weeks. In hot tropicalsystem in maintaining required bulb quality.
climates, the bulbs should be windrowed in such a wayA is used in combination with coldstorage to extend
to reduce the exposed surface to minimise damagethe storage life of onions. Recommended air
due to direct exposure to the sun. In wet weather, thecomposition and temperature regimes are summarised
bulbs can take longer time to dry and may developin Table 8. Spring onions generally tolerate higher CO2
higher levels of rots during storage. The side of theand O2 levels than bulb onions, and the levels of CO2
bulb in contact with wet soil or moisture may alsoand O2 combination required varies depending on the
develop brown strains or pixels, which reduce thestorage temperature (Table 9). Commercial CA
appearance quality and value. Obviously, successfulstorage of onion bulbs is limited partly because of
windrowing is weather dependent and thereforevariable success and inconsistent effects on bulb
cannot be relied upon for large scale commercial onionquality. However, high carbon dioxide (0-5%) and low
production business. Bulbs harvested for storageoxygen (1-3%) levels in combination with low
require in total 14-20 days of ripening or drying beforetemperature storage has been shown to reduce
being stored. Harvested onions may also be placed insprouting and root growth (SeaLand, 1991; Hardenburg
trays, which are then stacked at the side of the field toet al., 1990). The combination of CA storage (5% CO2,
dry. In some tropical regions, the bulbs are tied together3% O2) and refrigerated storage (1°C) also resulted
in groups by plaiting the tops, which are then hung overin 99% of the onion bulbs considered marketable after
poles in sheds to dry naturally.7 months storage; however, 9% weight loss occurred
Harvested bulbs can also be taken straight from the(Smittle, 1989).
field and dried artificially either in a store, shed, barns, orOnion response to CA storage varies among cultivars.
in a purpose-built drier. This method is commonly usedTherefore, experiments should therefore be conducted
when crops are stored in bulk but it can also beunder local conditions to determine the appropriate
applied to bags, boxed or bins. Under this method, bulbslevel of gas composition suitable for safe storage of
are laid on racks and heated air is rapidly passedlocal cultivars. CA storage generally increases the
across the surface of the bulbs night and daypungency of characteristic cultivars. For the 'Viladia
[O'Connor, 1979; Brice et al., 1997]. Drying may take 7-10Sweets' which are known for their sweetness and
days and is considered complete when the necks oflow pungency, the recommended storage conditions
the bulbs have dried out and are tight and the skinsare (Smittle, 1989): 1 ºC, 70-80% rh, 3% O2, 5% CO2,
shriek when held in the hand. The control of humidity92% N2, and ventilation rate of 5.m3.h-1.m3 of onions.
level in the store is critical. Under very high humidity,2.7    Processing
drying is delayed and fungal infection can increase.Onion bulbs are generally chopped into desired sizes
However, if relative humidity is too low (below 60%),and shapes using a knife. Many commercial devices
excessive water loss and splitting of the bulb outerare also available for chopping onions. In some food
skins can occur, resulting in storage losses andpreparations, the onions are blended with other
reduction of bulb value. Placing onions on wire mesh iningredients to produce the desired flavour.