STATE-OF-THE-ART WIRELESS VACUUM MAPLE SAP TUBING SYSTEM

We figured that you would want to know the process that ensures our gourmet maple syrup is the best-tasting and highest quality maple syrup available today.  We have done a lot of homework here at Sweet Brook Farm and in collaboration with the Red Bucket Sugar Shack, we have come up with a one-of-a-kind sugaring system.

In our research on maple sap collection, tubing systems have always used wires to support the lines through the sugar bush to prevent tube sagging.  Any sap left sitting in a sagging tube is a breeding ground for bacteria growth, so it is important to have taught sap lines so the sap can fully drain out.  Over his 40 years of sugaring, Jeff Mason of the Red Bucket Sugar Shack has developed a few easily fabricated methods to run tubes through the sugar bush without using wires.  The wireless tubing system is more economical to install and easier to repair should a tree fall down in a wind storm and take the lines down.  This is the methodology we have chosen to adopt in our maple production system.

Lateral lines are tied to the main lines using hollow nylon rope

This loop in the line is called a Drop

Starting with the tree, the lateral lines are hung through the sugar bush.  These are the blue 5/16” lines that are connected to the tree and flow into the main lines.  The loops are called drops.  These keep the system closed when the sap is not flowing.  When the taps are set into the tree every season, one end of the drop is hooked into the tap.

The lateral lines are tied to the main lines using woven, hollow nylon rope which keeps the lateral line taught while removing tension from the connection to the main line.  One end of the rope is tied to the main line, while the lateral line is threaded through the hollow rope.  Using the Chinese finger trap concept, the lateral line is pulled taught and held in place under tension.  The lateral lines can be easily loosened for repair or repositioning.

We connect the lateral line to the main line with a "stab-in" or "saddle"

Connecting the lateral lines to the main line is accomplished using a stab-in, or saddle.  A gasket in the saddle helps maintain a vacuum-tight seal.

Main lines are supported by 5/16" lateral tubing

The main lines are simply supported by loops of 5/16” lateral tubing and a nail.  Should a tree fall across the lines, the nail is pulled out of the tree, and falls down with it.  Repairs are made simply by cutting away the fallen tree and hammering the loop back into the supporting tree.

Lines with more tension are supported by logging straps

Where lines are under more tension and more strength is needed to support them, logging strap is used in a similar fashion as the lateral tubing loops.

Sometimes a main line has to bend around a tree which causes pinching of the main line.  A piece of PVC pipe cut vertically in half provides support for the bending line and reduces constriction in the line.

PVC pipe is used to prevent crimping when bending around a tree

The main lines are tied to trees and pulled taught using nylon rope threaded to specially fabricated washers.  In the summer time, the main lines relax in the heat, allowing the rope to relax, allowing the tree to grow without restriction.  This is better for the trees’ health.

Mainlines are tied to trees with rope to allow minimum growth restriction in the warmer months

This photo illustrates how the main sap and vacuum lines are supported using a series of the rope pulls as described above.  It’s important to have the tension pulling in both directions of the bend.

Proper bending of the main sap and vacuum lines

In several low-lying areas in the sugar bush, star ladders are used to get the sap up to a higher main line.  The vacuum in the system causes the gases in the sap to form bubbles that carry the sap up to the higher line where it can then drain out by gravity.

Star ladders are used in low-lying areas

Star ladders are used to get sap up to a higher main line

In other low-lying areas of the sugar bush, there are no higher lines for the sap to flow.  Vacuum can pull the liquid uphill from tub ladders through dedicated wet lines to the vacuum booster tanks.  Vacuum releasers dump the sap into the tubs, and a special foot valve in the bottom of the tub allow the wet line to pull a continuous column of sap as much as 20 feet up hill.

Tub ladders help pull the sap uphill

Main lines that carry the sap from the sugar bush terminate into vacuum booster tanks which allow sap to drain underground to the main releaser in the pump house while increasing vacuum to the main lines.  The protective frame around the tank prevents damage to the sensitive apparatus from falling limbs.

Main lines terminate into vacuum booster tanks

The main lines are color coded for easy identification and isolation of vacuum leaks.  Booster tanks can be disconnected after the season and stored inside to prevent damage from summer heat and sun.

Lines are color coded for easy identification

After flowing underground through 5,000 feet of trench below our meadows, the sap arrives at the pump house.  From there it is sent 1,400 feet directly to our sugar house for processing.

Sap travels underground to the pump house

Lines from the pump house run under our driveway up to the sugar house.

All of the lines run under our driveway

All sap is sent with minimum hold-up time to our sugar house for immediate processing.