Capturing Value with Cereal Rye: Growing High Quality Rye in the Northeast for Value-Added Markets

Objective 1: Determine the demand and market requirements for cereal rye across a variety of sectors. 

June Russel, Glynwood, Heather Darby, UVM Extension, Michael Moser, The UVM Center for Rural Studies, and Agricultural Economist Brian Baker started working on survey development in the fall of 2022. The goal was to develop and conduct a survey on the various emerging markets for regionally grown rye in the Northeast. The project team worked together in December of 2022 to develop a distribution list for the survey. The planned markets to be surveyed include food grade, distilling, seed (both cover crop and grain seed), and malting. The goal of the survey is to capture rye use and demand, varieties that are currently used, standards required for various market sectors, and general info on performance.

Rye End Use Survey. The project team executed the Rye End Use Survey in Qualtrics and distributed it through multiple membership organizations representative of the supply chain to reach the target audience of rye end users.  The researchers identified relevant and trusted organizations in the supply chain in the Northeast and North Central regions, as well as nationally.  These included: the Artisan Grain Collaborative, the Common Grain Alliance, the Craft Maltsters Guild, the Millers Peer Learning Group, the New York Distillers Guild, the Northeast Organic Farmers Association (NY), the Northern Grain Growers Association, and the Ograin Project. Each organization agreed to distribute the survey to their constituent email lists. The combined number of email addresses resulted in 16,022 contacts across all organizations. Because the lists were controlled by the different organizations, we were unable to identify duplicates nor to tailor the lists to ensure the survey’s relevance to any individual recipient; to address this, the email invitations asked end users to complete the survey only once. Given that the survey takes 10-20 minutes to complete, it is unlikely that any one end user would have taken it twice. The survey was distributed by email between February 14, 2023 and April 15, 2023. At least one reminder email was sent by each collaborating organization. The survey was closed on June 12, with a total of 102 responses in the project’s focus area of the Northeast. While the response rate was low for the size of the invitation pool, the researchers feel confident that we captured high quality responses from a sufficiently wide cross-section of end-users in the project’s focus area from which to extrapolate relevant data. 

Focus groups were conducted in the fall of 2023, which were additional to the original scope of work for the project. Four primary and secondary processor focus groups (Farmers, Maltsters & Distillers, Millers & Bakers, and Feed & Seed handlers) were convened in order to gather more detail and build additional context around rye production and processing.  Invitations were emailed to specific actors from each group to join a virtual call with a goal of four to six participants in each of the four groups. The Project team conducted four focus groups with a total of 11 participants:  three  farmers, two maltsters, two distillers, two bakers, one miller, and onefeed miller.  Questions, which were shared with participants prior to each group call, were designed to gather detail about production and processing challenges, quality requirements, varietal attributes and  preferences, grain supply, and market opportunities. 

Summary and reports.  Results of the survey were analyzed in the fall of 2023 and a draft report, and one-page summary have been written and are in review. These survey reports will be finalized in the first half of 2024, detailing market opportunities for cereal rye across sectors. The focus group report is also forthcoming in the first half of 2024.  

Objective 2: To determine which cereal rye varieties are most appropriate for various end-uses 

2023 Trial

The rye variety trial was initiated at Borderview Research Farm in Alburgh, VT in the fall of 2022. Plots were managed with practices similar to those used by producers in the surrounding area. Agronomic information is displayed in Table 1. The experimental design was a randomized complete block with four replicates. The field was plowed, disked, and prepared with a spike tooth harrow to prepare the seedbed for planting. Plots were seeded in 5’ x 20’ plots with a Great Plains Cone Seeder on 24-Sep 2022 at a seeding rate of 350 live seeds m^-2. Treatments were twelve varieties of cereal rye including Aroostook, Bono, CoverMax, Danko, Hazlet, ND Dylan, ND Gardner, Progas, Serafino, Spooner, Tayo, and VNS (Ruth) (Table 2).

Table 1. Agronomic and trial information for the rye cover crop variety trial, 2022-2023.

Table 2. Winter rye varietal information, Alburgh, VT, 2022-2023.

Starting on 18-May through 4-Jun, heading dates and flowering dates were recorded for each variety. On 1-Aug 2023, one day prior to harvest, three plant heights per plot were measured for each plot, excluding awns. Lodging was assessed visually as percent lodged, with 0% indicating no lodging and 100% indicating the entire plot was lodged. Grain plots were harvested at the Alburgh site with an Almaco SPC50 plot combine on 2-Aug. Seed was cleaned with a small Clipper M2B cleaner (A.T. Ferrell, Bluffton, IN) and a one-pound subsample was collected to analyze quality characteristics. Grain quality was determined at the E. E. Cummings Crop Testing Laboratory at the University of Vermont (Burlington, VT). Grains were analyzed for crude protein and starch content using the Perten Inframatic 9500 NIR Grain Analyzer (Perkin Elmer, Waltham, MA). The samples were then ground into flour using the Perten LM3100 Laboratory Mill (Perkin Elmer). Falling number for all rye varieties were determined using the AACC Method 56-81B, AACC Intl., 2000 on a Perten FN 1500 Falling Number Machine Mill (Perkin Elmer). The falling number indirectly measures enzymatic activity in the grain, which is typically used as an indicator of pre-harvest sprouting. It is determined by the time it takes, in seconds, for a stirrer to fall through a slurry of flour and water to the bottom of a test-tube. Deoxynivalenol (DON) analysis was done using Veratox DON 2/3 Quantitative test from the NEOGEN Corp (Lansing, MI). This test has a detection range of 0.5 to 5 ppm. Samples with DON values greater than 1 ppm are considered unsuitable for human consumption. Samples from one replicate were evaluated for DON and all samples tested below the FDA threshold for human consumption (1 ppm) (data not shown).

Standard characteristics were analyzed using mixed model analysis using the mixed procedure of SAS (SAS Institute, 1999).  Replications within the trial were treated as random effects, and treatments were treated as fixed. Treatment mean comparisons were made using the Least Significant Difference (LSD) procedure when the F-test was considered significant (p<0.10). 

Objective 3: To determine the optimum planting date and seed depth for cereal rye to maximize winter survival and yield/quality. 

2022 Trial

The rye planting date x seeding depth trial was initiated at Borderview Research Farm in Alburgh, VT in the fall of 2022. Plots were managed with practices similar to those used by producers in the surrounding area. Agronomic information is displayed in Table 3. Main plots planted using Hazlet rye were winter rye planting dates and split plots were seeding depths. The field was plowed, disked, and prepared with a spike tooth harrow to prepare the seedbed for planting. First planting date plots were seeded in 5’ x 20’ plots with a Great Plains Cone Seeder on 24-Sep 2022 at a seeding rate of 350 live seeds m^-2 with subsequent planting dates established approximately 1 week apart, varying as a result of weather and field conditions.

Table 3. Agronomic and trial information for the rye cover crop variety trial, 2022-2023.

After fall establishment, and prior to sustained freezing temperatures (9-Nov), percent ground cover was measured by processing photographs using the Canopeo© smartphone application. Additionally, tiller and plant counts were taken from 1, one-foot section within each plot to evaluate stand establishment on 10-Nov. On 3-Aug 2023, prior to harvest, three plant heights per plot were measured for each plot, excluding awns. Lodging was assessed visually as percent lodged, with 0% indicating no lodging and 100% indicating the entire plot was lodged. Grain plots were harvested at the Alburgh site with an Almaco SPC50 plot combine on 6-Aug. Seed was cleaned with a small Clipper M2B cleaner (A.T. Ferrell, Bluffton, IN) and a one-pound subsample was collected to analyze quality characteristics. Samples for each planting date at the 1.0” planting depth were saved for quality analysis to further determine potential impacts of planting date on rye quality. Grain quality was determined at the E. E. Cummings Crop Testing Laboratory at the University of Vermont (Burlington, VT). Grains were analyzed for crude protein and starch content using the Perten Inframatic 9500 NIR Grain Analyzer (Perkin Elmer, Waltham, MA). The samples were then ground into flour using the Perten LM3100 Laboratory Mill (Perkin Elmer). Falling number for all rye varieties were determined using the AACC Method 56-81B, AACC Intl., 2000 on a Perten FN 1500 Falling Number Machine Mill (Perkin Elmer). The falling number indirectly measures enzymatic activity in the grain, which is typically used as an indicator of pre-harvest sprouting. It is determined by the time it takes, in seconds, for a stirrer to fall through a slurry of flour and water to the bottom of a test-tube. Deoxynivalenol (DON) analysis was done using Veratox DON 2/3 Quantitative test from the NEOGEN Corp (Lansing, MI). This test has a detection range of 0.5 to 5 ppm. Samples with DON values greater than 1 ppm are considered unsuitable for human consumption. Samples from one replicate were evaluated for DON and all samples tested below the FDA threshold for human consumption (1 ppm) (data not shown).

Standard characteristics were analyzed using mixed model analysis using the mixed procedure of SAS (SAS Institute, 1999).  Replications within the trial were treated as random effects, and treatments were treated as fixed. Treatment mean comparisons were made using the Least Significant Difference (LSD) procedure when the F-test was considered significant (p<0.10). 

Objective 4: To determine the impact of nitrogen management on cereal rye yield and end-use quality.

2023 Trials

The rye fertility trial was initiated at Borderview Research Farm in Alburgh, VT in the fall of 2022. Plots were managed with practices similar to those used by producers in the surrounding area. Agronomic information is displayed in Table 4. The experimental design was a randomized complete block with split plots and four replicates. The field was plowed, disked, and prepared with a spike tooth harrow to prepare the seedbed for planting. Plots were seeded in 5’ x 20’ plots with a Great Plains Cone Seeder on 17-Sep 2022 at a seeding rate of 350 live seeds m^-2. Treatments consisted of varying application rates and periods (Table 5). Fall applications were made on 6-Oct 2022 and spring applications were made on 26-Apr in the form of calcium ammonium nitrate (CAN) 27-0-0.

Table 4. Agronomic and trial information for the rye cover crop variety trial, 2022-2023.

Table 5. Nitrogen fertility treatment application rates and times, 2022-2023.

On 8-Nov 2022, percent ground cover of rye plots was recorded for each treatment using the Canopeo© smartphone application to determine potential impacts of fertility applications on rye establishment. In the following spring (12-Apr 2023) percent ground cover was once again recorded to further evaluate application rates and winter kill for each plot. Biomass samples were collected on 11-May alongside soil nitrate samples. On 26-Jul 2023, three plant heights per plot were measured for each plot, excluding awns. Lodging was assessed visually as percent lodged, with 0% indicating no lodging and 100% indicating the entire plot was lodged. Grain plots were harvested at the Alburgh site with an Almaco SPC50 plot combine on 31-Jul. Seed was cleaned with a small Clipper M2B cleaner (A.T. Ferrell, Bluffton, IN) and a one-pound subsample was collected to analyze quality characteristics. Grain quality was determined at the E. E. Cummings Crop Testing Laboratory at the University of Vermont (Burlington, VT). Grains were analyzed for crude protein and starch content using the Perten Inframatic 9500 NIR Grain Analyzer (Perkin Elmer, Waltham, MA). The samples were then ground into flour using the Perten LM3100 Laboratory Mill (Perkin Elmer). Falling number for all rye varieties were determined using the AACC Method 56-81B, AACC Intl., 2000 on a Perten FN 1500 Falling Number Machine Mill (Perkin Elmer). The falling number indirectly measures enzymatic activity in the grain, which is typically used as an indicator of pre-harvest sprouting. It is determined by the time it takes, in seconds, for a stirrer to fall through a slurry of flour and water to the bottom of a test-tube. Deoxynivalenol (DON) analysis was done using Veratox DON 2/3 Quantitative test from the NEOGEN Corp (Lansing, MI). This test has a detection range of 0.5 to 5 ppm. Samples with DON values greater than 1 ppm are considered unsuitable for human consumption. Samples from one replicate were evaluated for DON and all samples tested below the FDA threshold for human consumption (1 ppm) (data not shown).

Standard characteristics were analyzed using mixed model analysis using the mixed procedure of SAS (SAS Institute, 1999).  Replications within the trial were treated as random effects, and treatments were treated as fixed. Treatment mean comparisons were made using the Least Significant Difference (LSD) procedure when the F-test was considered significant (p<0.10). 

Objective 5: To determine the impact of harvest date on cereal rye yield and end-use quality.

2022 Trial

The field was plowed, disked, and prepared with a spike tooth harrow to prepare the seedbed for planting.  The experimental design was a randomized complete block with split plots and 4 replicates. The main plots were harvest date and the split plots were variety. The plots were planted with a Great Plains cone seeder on 22-Sep 2021 and plots were 5’ x 20’ (Table 6).

Table 6. Agronomic and trial information for the rye cover crop variety trial, 2021-2022.

Grain plots were harvested with an Almaco SPC50 plot combine at one week intervals from 20-Jul through 12-Aug. Following harvest, seed was cleaned with a small Clipper M2B cleaner (A.T. Ferrell, Bluffton, IN). Grain moisture, test weight, and yield were measured. A subsample (approximately one-pound) was collected to determine quality. Quality measurements included standard testing parameters used by commercial mills. Grains were analyzed for protein and starch content using the Perten Inframatic 9500 Grain Analyzer. Rye flour for baking should have starch content between 56–70% and protein content between 8–13%. Samples were ground into flour using the Perten LM3100 Laboratory Mill. Falling number was measured on the Perten FN 1500 Falling Number Machine (AACC Method 56-81B, AACC Intl., 2000). The falling number is related to the level of enzymatic activity and sprouting damage that may have occurred in the grain. It is measured by the time it takes, in seconds, for a stirrer to fall through a slurry of flour and water to the bottom of a test tube.

2023 Trial

The field was prepared with a Pottinger TerraDisc® to prepare the seedbed for planting.  The experimental design was a randomized complete block with split plots and 4 replicates. The main plots were harvest date and variety the split-plot. The varieties evaluated were Bono, Danko, Hazlet and Serafino. Rye was planted with a Great Plains cone seeder on 17-Sep 2022. Plots were 5’ x 20’ (Table 6).

Table 6. Agronomic and trial information for the rye cover crop variety trial, 2019-2020.

Grain plots were harvested with an Almaco SPC50 plot combine at approximately one week intervals through the end of July and beginning of August. Following harvest, seed was cleaned with a small Clipper cleaner (A.T. Ferrell, Bluffton, IN). Plot yield was weighed on a pound scale. A one-pound subsample was collected to determine quality. Grain quality was determined at UVM Extension’s E. E. Cummings Crop Testing Laboratory (Burlington, Vermont). Grains were analyzed for protein and starch content using the Perten Inframatic 9500 Grain Analyzer. The samples were then ground into flour using the Perten LM3100 Laboratory Mill.  Falling number was determined using the AACC Method 56-81B, AACC Intl., 2000 on a Perten FN 1500 Falling Number Machine. The falling number is related to the level of sprout damage that has occurred in the grain. It is measured by the time it takes, in seconds, for a stirrer to fall through a slurry of flour and water to the bottom of the tube. Deoxynivalenol (DON) analysis was analyzed using Veratox DON 2/3 Quantitative test from the NEOGEN Corp. This test has a detection range of 0.5 to 5 ppm. Samples with DON values greater than 1 ppm are considered unsuitable for human consumption. One sample from each variety from each harvest date was tested for DON levels and all were determined to be above the 1 ppm threshold for consumption.