Author-Editor:

CEDEPAS North
Los Corales 289 Santa Inés Urbanization
1a. edition - January 2018
LEGAL DEPOSIT MADE IN THE NATIONAL LIBRARY
OF PERU N° 2018-00903

It finished printing in February 2018 in CM

PUBLICIDAD Y NEGOCIOS SAC
Mz. Q Lt 24 Los Pinos Urbanization
Trujillo – Trujillo – La Libertad

2
 Index
CONCEPTS AND DEFINITIONS OF THE CABLE TRACK SYSTEM

A General aspects of the via cable

B What is via cable?
C Benefits of cable track
D Parts of the track cable
E Aspects that must be taken into account for the construction of the cable via
F Track Cable Specifications

2. HANDLING AND USE OF THE VIA CABLE

A Definition
B Procedures for using the cable via
C Recommendations

CABLE 3. TRACK MAINTENANCE

A Definition
B Track Cable Maintenance Procedures
C Recommendations

4. CONCLUSIONS

3
In the different coastal valleys, the importance of using cable-via technology in the organic banana production process managed by
different banana organizations has emerged; who at the same time provide this service to their partners to improve the quality of the
product, and in this way reach more demanding markets. This technology will also contribute to small farmers being able to undertake
a competitive business model, which allows them to communicate with the most demanding foreign markets in terms of product
quality, which will result in obtaining better monetary income.

In this framework, Cedepas Norte in its capacity as CITE Agropecuario with the support of the APC Japan program presents the
manual for the use and maintenance of the cable track, which has the purpose of guiding its operation and positioning in banana
organizations.

The purpose of this Manual is to present in a simple and didactic way all the aspects related to the characteristics, operability, and
advantages of using cable via in banana organizations.

Through this document, we seek to provide agro-entrepreneur producers with practical knowledge of all aspects related to the
operation and the advantages that the appropriate and efficient use of cable via represents for the organic banana process.

4
1.- CONCEPTS AND DEFINITIONS OF THE CABLE TRACK SYSTEM

TO. GENERAL ASPECTS OF THE CABLE VIA

The cable-via system is valuable for producers, because it allows them to reduce the discarding of organic bananas in
the post-harvest, thus giving them a greater profit margin.

This system must be designed in such a way that it facilitates the

operator's movement within it and among the clusters. It must have
an approximate height of 2.20 meters above the surface and
supported by arches of galvanized tube or immunized wood, placed
between 8 and 10 meters for greater resistance and durability. The
cable must consist of a rod of approx. 7/16 inch in diameter and with a
resistance of 100kg per mm to avoid the risk of breaking and
subsequent falling of the clusters.
The cable track is a transportation system that allows the transfer of the
bunch as well as equipment, materials and inputs, from the
plantation to the baler or vice versa. It is a network of cables made
up of a main cable and several secondary cables depending on the
drainage channels. The construction of the cable track is
essential (although not mandatory for very small farms). This
system must be designed in such a way that it mainly allows the
internal logistics of transporting bunches as well as equipment,
materials and supplies.

b. WHAT IS CABLE VIA?

C. BENEFITS OF CABLE VIA

□ Adaptability and flexibility for the transfer of the bunch.

□ Reduces harvest operating costs.
□ Considerably reduces damage to fruit during transport.
° Allows the transport of fruit in different climatic conditions and/or the terrain itself.
° Transfer to greater distances and in less time.
□ Facilitates the post-harvest process during work in the packaging center.

5
D. PARTS OF THE CABLE TRACK
□ Galvanized Arches: These are the ones that support the cable, they are located 10 meters away and their height is
2.20 m.
□ 11.11 mm steel cable: It is the line that allows us to transfer the bunches to the packaging center.
□ Cement blocks (Biscuits): They are used to support the arch.
□ Zeta-shaped hook: Hook that hangs from the tower to support the cable.
° Chanela oVincha: Secure the cable to the hook.

6
 External parts of the cable via:

° Hoists: They are used to transport the clusters on the cable track, maintenance must be carried out after 12 to 18
months of use.
□ The toothpick or stick separator: As its name indicates, it is used to separate the sticks. It has a measurement of 1.20
meters. and it is made of ½ galvanized pipe

A ASPECTS THAT SHOULD BE TAKEN INTO ACCOUNT

N FOR CONSTRUCTION:

□ It must have an approximate height of 2.20m above the surface with a slope of no more than 10
degrees towards the baler, and supported by arches of galvanized pipe or immunized wood,
placed between 8 and 10m for greater resistance and durability.

□ The cable can be made up of a steel rod approximately 7/16 of an inch in diameter and with a
resistance of 100kg per mm to avoid the risk of breaking and subsequent falling of the bananas.

□ The cable must undergo frequent cleaning and continuous maintenance.

F. TRACK CABLE SPECIFICATIONS

The cable track is a monorail where the load moves hanging on wheels supported by a taut wire supported by multiple towers
low above the ground. It is located uniformly within the plantation and is oriented parallel and equidistant from the secondary
7
 channels, so that the maximum distance to transport the fruit by the person is not greater than 65 meters, on average it is 40 to
50 meters. meters. The most important thing includes coordination with the drainage system, highlighting the placement of
bridges, which should be minimal in terms of quantity and cost. The planning of the cable track system must start from the
packaging plant with a point of origin, especially at 2.10 meters above the floor interconnected with the warehouse system.

From this point on, the cable must maintain its level with all points of the plantation, with slight differences, which if they occur
must be with a difference in level towards the packing plant, but never in the opposite direction; since this would cause greater
effort in transporting the harvest. A contour plan of the area to be developed is essential to know the topographical accidents that
can modify the system, it must be treated by all means available to ensure that the cable remains more or less than 2.10 meters
high above the ground. , since higher heights make it difficult to load the fruit and lower heights make it impossible for the
bunches to pass over the ground. The first cable to build is the main cable and it must maintain its level between the packing
plant and its final point. This cable will be used as a base in levels to build the secondary or branch cables that will enable the
entire plantation.

CABLE TRACK COMPONENTS

The components of the cable track are steel cable or wire, anchors, terminal supports, towers, zetas, gates, and reinforced
concrete tiles.

STEEL CABLE OR WIRE:

The steel cable or wire is a solid wire rod of 11.11 mm in diameter and with a resistance of 77/97 kg/mm2 and a tension of 7.0
kg/mm2.

This steel cable or wire is specially built to transport bananas and is built in rolls of lengths of 200 to 400 meters, so it is
necessary to join them at their ends with very high resistance welding.

TERMINAL SUPPORTS:
Once the cable has been extended in the place it will occupy, one of the ends will be fixed to a support post, the height of which
must be at the level of the packaging plant or with the main cable.

This post can be a portion of rail or any galvanized iron steel structure measuring 2”x 2.30 meters high with the capacity to
sustain the indicated tension.

This post or support will be held in its position but slightly inclined in the opposite direction to the cable, by means of an anchor
consisting of a steel cable fixed to the ground, by means of a mass of reinforced concrete (tile of 40 x 40 x 10 cm.) 10 meters
from the base of the support post.

Once the cable is fixed to the supports, tension will be applied to one of its ends, using specialized equipment for this work. The
tension may vary between 5 and 7 kg/mm2, depending on the length and the amount of work to be done. In fact, the main cables
need more tension than the secondary ones due to their great weight, the cables require temporary supports every 30 meters to
achieve the proper tension. Once the cable is tensioned, its end is fixed to the post using high-strength steel staples. The tension
is by using a pressure gauge.

ARCHES AND TOWERS:

The cable is kept level by support towers located every 9.00 meters, on the cable line and every 2.00 meters when there is a
curve. The towers are generally arches of Ø 11/4” galvanized pipes fixed at their ends to the ground by reinforced concrete tiles
30 cm wide by 30 cm long and 5 cm thick.

The tower is formed by the arch, the zeta, the plate, the tile and the fixing rod. The towers are placed one by one and leveled at
their feet so that the cable rail remains level and functional.

8
 The topographical differences of the terrain will make some towers taller than others and may vary from the minimum height of
2.10 meters.

THE ZETA:
It is a piece of corrugated iron rod ¾” Ø° x 31 cm long, shaped in such a way that it supports the cable and fixes it at the top of
the tower using a rigid system, since the cable can move slightly to the sides, which is allowed by the support tube fixed to the
top of the tower without fixing the Zeta.

At the bottom, the cable is supported by a small ½” x 1” iron plate, welded to the zeta vertically and in the direction of the cable,
the cable is kept in possession by a small galvanized steel sheet, called a winch that wraps the cable and is fixed at its ends to
the support by ¼” x 1” screws.

During leveling, care must be taken that all the zetas are on the same side, so that the rounds or rails can pass freely without
hitting them.

GARRUCHAS OR RONDINES:
They are wheels supported on a taut wire supported by multiple towers where the load moves hanging from these wheels at a
low height above the ground. They are fixed using ½” galvanized pipe spacers. To move 20 pulleys, 19 ½” x 1.0 meter long
separators are used.

9
 REINFORCED CONCRETE TILE:
The concrete tiles F'c = 175 Kg/cm2 of 30 x 30 cm and 5 cm
thick. The tile has a hole in the center that allows the foot of the
tower to freely pass through, which is fixed by a ½° rod 10 cm
on each side with a thickness of ½° and a central hole,
whose diameter is greater than 5 cm. than the one in the
tower. In the space left in the gap of the plate and the foot of the
tower, an iron wedge is inserted that does not allow the tile to
move downwards with the load.

The gate is a rotating structure that is used to cross a

roadway in the transportation of bananas. The gate is made up of
a 4” x 2” x ¼” folding “U” channel, where the cable is
welded.

The “U” channel is supported by a hinge on a post which has

GATES:
temples to hold it in position and thus when crossing the
roadway, when hooked to the cable and with the
corresponding insurance, production passes. Then, the gate
is unhooked and rotated to leave the roadway free.

2 .- HANDLING AND USE OF THE VIA

CABLE
The cable track comes into operation when 20 poles are loaded with bunches of banana (one bunch per pole),
subsequently these 20 loaded poles are pulled by one person to the packaging center, each pole carries one bunch of
banana which weighs one average of 35 kilos; Therefore, each person responsible for pulling can carry 700 kilos to the
baler. While in the traditional system you can only carry 01 bunch of 35 kilos at a time. Each pulley is designed to support
up to 50 kilos.

T DEFINITION
b.
O.
CABLE VIA USE PROCEDURES

Step 1.
Monitor the condition of the cable infrastructure before being used.

10
 Step 2.
Place 20 winches and separators on the cable so that each operator can use the winch (It will depend on the number of
operators the crew has).

Step 3.
Place a cluster for each pole that is placed on the track cable.

Step 4.
The operator will verify the 20 clusters that are placed on the pole.

Step 5.
The operator stands in front of the clusters already placed on the pole; and pull with a rope in the direction of the
packaging center.

Step 6.
The operating person during transit will change the line and use a gate if necessary to reach the packaging center.

Step 7.
The operator must reduce the movement of the transfer every time it passes through a curve in the cable track and avoid
detachment of a pulley.

Step 8.
Once the operator has arrived at the packing center, he must leave the bunches in the weeding line.

Step 9.
The operator must assemble his 20 pulleys on the cable track and carry out the entire transfer process again until the
planned harvest is finished.

c. RECOMMENDATIONS
Carry out a harvest projection that allows us to have the necessary personnel and avoid cost overruns, taking into account that with
the use of cable the progress is significant.

For the use of the cable via the operating personnel must be trained and in case of change of a part of the operating people they must
also be trained before joining the work of the crew.

The operator who occupies the role of garruchero must have protective equipment such as: helmet, glasses, boots and gloves.

Once the harvest is finished, all the poles and separators used must be removed and cleaned to be stored and kept in optimal
conditions for the next harvest.

11
3 .- CABLE TRACK MAINTENANCE

T DEFINITION
O. of the cable track system consists of having all parts of the cable in optimal conditions, including what is
Maintenance
around it, in order to keep it always operational and available for use throughout the year; since in addition to using it at
harvest time it also serves to transport materials and inputs used in the agronomic management of organic banana
cultivation.

Maintenance of the track cable is recommended to be carried out 18 to 24 months after it has been installed and/or
before, if necessary; since the conditions of use are different in each area where it is installed.

Carry out preliminary work according to each part of the cable track to which maintenance will be carried out and for this
the following must be taken into account:

1 . Construction of zetas and/or hooks, cutting, bending and drilling of plates, cutting of headband and drilling, putting
on bolt and securing.

2 . Construction of reinforced concrete blocks with corrugated steel grill to support funicular tube (biscuits), support of
tempering tube (tile and/or angel), support of track cable tempering (shoe and/or dead).

3 . Construction of tempering, cutting and welding of ø ¾“ iron.

4 . Construction of parking lot towers, coiling and welding of funicular tube and placing zetas in parallel. This area will
be roofed.

12
 b. CABLE TRACK MAINTENANCE PROCEDURE

Cable Retempering
This maintenance work must be carried out every 12 to 18 months,
re-tempering the line, for a better transfer of the bunches, using a 5
Tn tool (type) to be able to temper the cable and a welding machine
to join the cut cable for proper retempering, splicing said cut with a
2”x ¼ plate where the “Z” is preferably placed.

Align Arcs.

It consists of preventing the approach of banana plants to the supports

(Cookies) so that they do not harm the position of the arches in the sections of the cable track installation and/or changing its
position to avoid damage from falls. the clusters.

The zeta or hook:

For better use of the zetas (Z) or hooks, when transporting
products (fertilizers), we must avoid distributing the load,
avoiding maintaining a single pressure on only one side,
this causes breakage of the horns, harming the transfer of
the bunches. to the process center.

Temper Anchor:
Avoid digging near the anchor of the final tempering device to avoid
distempering the track cable, as this could cause serious personal injury.

13
 Chanela or headband:
The chanela or zeta headband is recommended made of galvanized
steel because its function is to join the track cable with the zeta, its
maintenance or change must be carried out after 12 to 18 months, of
continuous usefulness of the track cable.
1 . Do not use the arch as a tempering of productive bushes, nor
to mark the separation of a plot of land.

2 . Keep the cable track paths clean, carrying out quarterly

weeding.

c. RECOMMENDATIONS

3 . Eliminate plants that approach the arches of the cable track.

4.1 identify the danger zones of the cable track, with informative signs and/or painting with highlighting colors.

5 . Lubricate the track cable when required.

6 . Maintain the garruchas to have a better distribution at the time of harvest.

4.- CONCLUSIONS

Due to its permanent use, the track cable requires constant maintenance: consisting of the following tasks: .

a)Cable oiling: In very rainy areas it is advisable to apply lubricating oil every two weeks, while in areas with low rainfall it
can be done every three months. .

b) Steel sheets: The condition of the steel sheets for fixing the cable in the zeta must be checked frequently so that they
do not suffer wear with use or that one of their fixing screws could be lost, since a breakage of One of these components
causes the cable to be loose from the arc, with the logical drop of the load at the moment of its passage.

c)The arches must be leveled frequently if the ground has given way due to the weight of the load or excess humidity. .

d) The transport of excessive loads more than the permitted limits (70 Kg/pole) should not be allowed. Too much concentration of
load can break the zetas, the cable or unevenness the arches, the load being transported, which is different from the bunches of
banana, it must be distributed uniformly on as many supports as possible.

Index 3
4. 3
1.- CONCEPTS AND DEFINITIONS OF THE CABLE TRACK SYSTEM 5
TO. GENERAL ASPECTS OF THE CABLE VIA 5
14
 b. 5
C. BENEFITS OF CABLE VIA 5
D. PARTS OF THE CABLE TRACK 6
External parts of the cable via: 7
ASPECTS THAT SHOULD BE TAKEN INTO ACCOUNT FOR CONSTRUCTION: 7
F. TRACK CABLE SPECIFICATIONS 8
CABLE TRACK COMPONENTS 8
TERMINAL SUPPORTS: 8
ARCHES AND TOWERS: 9
THE ZETA: 9
GARRUCHAS OR RONDINES: 9
REINFORCED CONCRETE TILE: 10
2 .- HANDLING AND USE OF THE VIA CABLE 10
TO. 10
DEFINITION 10
CABLE VIA USE PROCEDURES 10
Step 1. 10
Step 2. 11
Step 3. 11
Step 4. 11
Step 5. 11
Step 6. 11
Step 7. 11
Step 8. 11
Step 9. 11
c. 11
RECOMMENDATIONS 11
3 .- CABLE TRACK MAINTENANCE 12
TO. 12
DEFINITION 12
CABLE TRACK MAINTENANCE PROCEDURE 13
Cable Retempering 13
Align Arcs. 13
The zeta or hook: 13
Temper Anchor: 13
Chanela or headband: 14
c. 14
RECOMMENDATIONS 14
4.- CONCLUSIONS 14
"One Town, One Product" for the Installation of the Production System of organic bananas for export in Pacanga La
Libertad 17
□
15
"One Town, One Product" for the Installation of the Production System
of organic bananas for export in Pacanga La Libertad

PERU agricultural
Ministry QUOTE cepas nn) f
eoumérloo center of U
Production Id promotion and social action IIU
UU
t
Cedepas Norte