Wrapped Bale Silage for High Silage Quality

Silage is made on most farms but, surprisingly, less than half conserve it in the form of wrapped bales. With this is mind we asked Nigel Ford of All Things Rural to set out the basic ground rules for anybody considering introducing balewrapping technology to their farming system. 

Producing silage is no longer considered just another seasonal job but is now regarded as a highly developed science that requires care and attention.

During the 1970’s the first polyethylene silage bags were used in the UK. Results were variable, due to excess air left inside and difficulty sealing the neck of the bag. Around 1985 the benefits of wrapping silage bales in balewrap stretchfilm were recognised and launched in the UK on a large scale. They quickly replaced the laborious system of bagging. The machinery steadily improved and led to the latest generation of automated wrappers. The system has proved popular and now accounts for an increasing share of the total silage market.

Why preserve by wrappingEach wrapped silage bale is in effect an individual silo. This means that each crop can be harvested and preserved individually according to its maturity as opposed to bulk silage, where crops of different nutritional values are likely to be together. This enables material of high yielding autumn calvers whereas lower value crops would be better suited to dry cows.

The wrapped silage system is very flexible. Bales are easy to store and can be left in several locations around the farm. The likelihood of effluent is extremely small because each bale is sealed and usually has a higher dry matter content than clamped silage. Of course, compared with haymaking the results are less dependent on fine weather. Additional investment in wrapping machinery may be required but these initial costs can be avoided by using contractors.

Wrapped silage is transportable and therefore can provide a cash sale in times of surplus. Where summer grass is scarce it can prove invaluable. Bale wrapping is an ideal way to preserve surplus silage on farms where bulk storage is in use and the clamps are full. In these situations it can also be useful when only a few animals are being fed, when it would not be ideal to open the clamp.

Cutting for silage

Wrapped Bale Silage for High Silage QualityWhen ensiling forage it is important to preserve as much of the nutritional value as possible. The nutritional value of the crop can be defined as the energy and protein content per kg of DM. Feed intake and live weight gain of livestock will be affected by it. And so the nutritional value is affected by the crop, the time of harvesting, choice of fertilisers and also the degree of accuracy of harvesting and preservation processes.

When crops are cut early and there is a balance between energy and protein they will have a high nutritional value. Timing of harvest is critical. Normal sugar-rich grass crops, intended for silage will give good results. On the other hand, the practise of wrapping late cut hay to save it from rain can result in extensive mould spoilage.

Clean crops are of vital importance to producing hygienic forage. Contamination can have a disastrous effect, even in a completely oxygen free bale. Losses can be extensive if fungi are exposed to air inside the bale allowing moulds and spoilage to occur.

For example, even a dead rabbit can cause contamination if picked up in the bale and represents a danger of the very toxic poison, botulin, an anaerobic organism that thrives in the absence of air. This is a high risk with bales of low dry matter content. Feeding this silage can have fatal consequences.

Farmyard manure spread at the wrong time can also create problems and applications are best carried out before the crop starts actively growing.

One of the ways to prevent the growth of undesirable bacteria is with the correct degree of wilting and the careful use of suitable additives. By ensuring the bales are as dense and well shaped as possible, so that the air spaces within are small, fungal growth can be minimised. Whole crop and maize has been successfully wrapped but it is generally more difficult to compress these ‘coarse’ crops sufficiently with existing balers.

Mowing and wiltingThe timing of cutting is important to retain nutritional value and also to enable the baler to adequately compress the crop and produce a dense, well-shaped bale. Although the weather will determine time of cutting, mowing should take place just as the seed heads start to appear on the grass crop.

Once the crop has been cut, moisture will be lost through evaporation. Moisture loss is greatest during the first hour or two immediately after cutting and it may be desirable to cut and spread grass before rowing up. However, it is important not to contaminate the forage with soil and other debris as this will lead to poor quality silage.

In favourable conditions, the aim should be for a wilting period of no more than 24-36 hours. Do not leave the swath for more than 2-3 days but if this is unavoidable a suitable additive should be used. In damp, warm conditions moulds grow rapidly in the swath.

Wilting is one of the most important phases of successful baled silage making. It is important both for good fermentation and sufficient bale density. A DM content of between 35-45 per cent should be obtained to get good results. For wrapped silage, there should be no need for additives beyond 40 per cent DM. if moulds do occur under these conditions; they are likely to be because of poor wrapping or damage to the film after wrapping.

Wilting also affects bale density, which is directly related to the degree of compression. During the short period of time involved in compression of the crop no baler can dehydrate the plant entirely. However, if the cells have already been dehydrated, the baler then has a good chance of producing dense, well-shaped bales.

It is important to bear in mind that though some bales of low dry matter may be heavy; they are not necessarily dense. Correct DM content is essential to minimise labour, machinery and film costs. Well-wilted bales keep their shape after good compression and can be stacked without problems.

AdditivesWhere weather conditions are not good and the crop is deteriorating rapidly, an attempt to salvage as much as possible must be made. Wet crops are at high risk of bacterial growth. This is where additives come into their own.

Formic acid is an organic additive that hinders the growth of negative micro-organisms and decreases the pH level of the crop.

Salts of both inorganic and organic acids are available for application in powder and liquid form. Sodium nitrate and hexamethylene tetramine will help prevent microbial growth, especially that of clostridia. Molasses, a natural product containing 50 per cent sugar, is added to stimulate lactic acid production by boosting the existing level of fermentable sugars. It is safe to handle and being of a high density, it has a positive effect on bale density by filling in air spaces. The crop should be wilted to DM content where there will be no effulent. 

The use of inoculants, which are freeze dried lactic acid producing bacteria, has become common in recent years. The idea is to add a high concentration of the bacteria in a water solution when baling.

The Stretchfilm

Stretchfilm for bale wrapping must be of high quality in order to meet a number of requirements. It should include UV stabilisers to avoid film degradation in strong sunlight and have a high level of tack to help ensure the cut end sticks to the bale and the seal remains intact during storage.

Trials have shown that lighter coloured film such as pale green or white reflects more sunlight than black film, which absorbs it. This can cause great variations of temperature within the bale and nutrients can be damaged as a result. Also lighter coloured film has fewer tendencies to overstretch in hot weather ensuring better overlap in film layers.

By tightly applying 6 layers of good quality stretchfilm the circulation of oxygen is considerably reduced. The resulting lower nutritional losses are reflected in savings, which can be considerable when compared with the cost of the film.

Handling and StorageCareful handling and storage of bales is important to ensure that the film remains undamaged and tight. It is useful to remember that the overall thickness of 6 layers of film will only be about 0.1mm. To protect the film, a purpose built handler is therefore necessary.

Round bales are best stored upright, as there is much more film on the flat ends for protection. Bales of high low dry matter should be stored in single layers to avoid pressure on the seals of the lower bales if they are stacked.

Wrapped square bales should be stacked immediately after wrapping and any bales which are ‘banana shaped’ should be stacked with the concave side facing downwards.

If the film is to remain tight and undamaged bales must be protected from birds and other animals. A storage site away from trees should be selected and a bed of fine material such as sand should be used as a base. If the site is in a field with farm animals a fence should be erected around the bales.

Making the best wrapped bale silage

WITH advice from experts, plastic producers and machinery manufacturers, James Rickard compiles top ten tips for round bale wrapping.

Swath and bale density

Good wrapping techniques start with baling – a badly shaped round bale cannot be wrapped properly, says Claas baler specialist Ian Brydson.

He says bales should be dense and cylindrical in shape, not bulging in the middle or conical shaped, and to achieve this crop flow is key – starting with the swath.

Mr Brydson says: “It should be uniform in shape and cover the full width of the pick-up reel – an operator shouldn’t have to weave around chasing narrow rows.”

Developments in baler technology have also made a big difference. “Roller crop presses and intake rotors, which force material into the chamber, really help with bale density.

“The density gap between fixed chamber and variable chamber round balers has also dramatically narrowed over the years. It really depends on crop type as to which one you use rather than bale density now.”

He adds maintenance and set-up are also factors in producing decent bales. “The baler should be serviced regularly and the chamber density set according to the crop.”

Dr David Davies, a director at Silage Solutions, says higher bale density can also be achieved with chopping. “Chopped bales are at least 10 per cent heavier than their unchopped counterparts helping to reduce the cost of production.

“Other advantages include a reduction in the amount of oxygen trapped in the bale and it releases sugar, which encourages a more rapid lactic acid fermentation. Both factors increase silage quality and reduce the risk of undesirable microorganisms, such as yeasts, moulds and listeria.”

Film stretch

To prevent downtime and inefficient use of plastic, several pre-season and in-season checks can be made.

Lloyd Dawson, a BPI Minster Films sales manager, says: “Bale wrapping machinery is like every other type of machinery – a long period without use can encourage decay and increase the risk of important parts failing once it is back in use.”

Before use, Mr Dawson recommends:

• All moving parts are free, in particular the Pre Stretch Unit (PSU) which can cease or stiffen up out of season.
• Check PSU and turntable gearing for wear and tear.
• Check PSU rollers for any damage and thoroughly clean down with de-greaser.
• Check PSU springs and replace if necessary. Dosed springs, dirty or worn-out rollers will cause aquaplaning, film tearing and uneven film application.

The correct amount of film stretch can be measured (see diagram A), and adjusted if necessary, by wrapping a straw bale before the season starts, says Mr Dawson. To do this, make two marks horizontally on the film reel 100mm apart. Slowly commence wrapping and locate these marks on the bale surface and measure the distance between them. For example, for 70 per cent stretch, the marks should be 170mm apart (see diagram B).

Overlap

Film wrap manufacturer Silotite says film overlap should be no less than 50 per cent.

To achieve this, check that when on the wrapper, the centre of the bale is horizontally in-line with the centre of the film reel (see diagram C). Wear and tear of all belts should be checked and even if only one of them is damaged or worn they should be replaced.

Silotite says badly aligned and worn belts will affect overlap.

Number of layers

Ensure a minimum of four layers is applied to bales with up to 50 per cent dry matter, and at least six layers for those over 50 per cent dry matter and coarse crop natured bales, says Silotite.

A recent experiment, undertaken by the Institute of Grassland and Environmental Research, demonstrated using six layers instead of four improved fermentation, created a better oxygen barrier and reduced moulds and dry matter losses.

However, it also revealed eight layers to be excessive. The extra cost was calculated at £0.71 per bale for six layers and £1.43 for eight layers. The cost saving in terms of the extra dry matter and sugar recovered was calculated at £1.37 and £2.52 respectively.

In return on cost terms, six layers gives 92 per cent but eight layers achieves only 76 per cent.

Where to wrap and handling

Wrap at the stacking area if possible, but if not, move bales from the field immediately after wrapping.

Dr Davies says: “Once forage has been harvested, the single biggest factor affecting silage quality is oxygen. If oxygen penetrates a bale it can cause reduced fermentation quality, increased losses of dry matter and nutrients, wastage due to mould growth and sometimes animal health problems.”

Mr Brydson says due to baler and wrapper developments, many farmers and contractors often wrap in-field.

Dr Davies adds while most will be aware of the importance of not damaging the wrap, many will be unaware of the potential problems of incorrect bale handling.

He says: “Even when using a squeezer, oxygen will enter a bale every time it is handled. This is because as the grab squeezes the bale to lift it, the gasses inside the wrap are pushed out. Once the bale is released, air from outside is sucked back in to fill the vacuum left behind.

“If silage bales are moved within the first eight hours of wrapping, then the use of a bale grab will have less of an adverse affect. This is due to the gases inside the wrap still being very similar to those outside. A denser-made bale will change shape less resulting in less gas exchange.”

Dr Davies also warns extra care should be taken when dropping bales off the wrapper. “One of the biggest problems is the stubble left in the field which, as bales drop off the wrapper, can puncture the bale as it lands. This is more of a problem with stalky crops, such as barley pea mixtures, etc.”

Wrapping at the stack is considered the best option, says Dr Davies. However, this method is not without its own problems. “Often unwrapped silage bales are moved to the stack by spiking, greatly increasing the risk of oxygen-related problems by creating a core through the centre of the bale,” he says.

“Also, if the wrap is damaged at a later stage, that central core is likely to become a centre for mould growth. As a result farmers should avoid spiking whenever possible, even unwrapped bales.”

Storage and protection

Once wrapped, the correct storage of bales is vital to preserve and retain the quality and nutritional value of the feed.

BPI Minster Films sales director Barry Buckley offers these stacking and storage tips:

• Stack bales as soon as possible after wrapping – certainly within 24 hours.
• Remember field-wrapped bales are particularly prone to bird damage from the moment they are wrapped.
• Choose a storage site away from trees and very exposed areas.
• The site should be well-drained, level and devoid of sharp objects.
• If practical, a sand base layer is recommended. Ideally, roll out a protective layer of heavy gauge polythene sheeting underneath the stack.
• Where necessary, protect the stack from farm animals with suitable fencing.
• Vermin should be discouraged by placing weather-protected bait stations around the stack perimeter. Ensure these are also protected from pets and farm animals.
• Once stacked, always protect from birds by applying a close woven polypropylene net. Support the net so it is not in direct contact with the surface of the bales where birds could land and reach through the net.
• Do not store bales near watercourses. Advice is available from your local water authority.
• Keep fertilisers, herbicides, mineral oils, etc. away from the stack as these can damage the film.
• Do not stack bales more than three high. Bales of low dry matter (heavier) should be stored in a single layer. This prevents bales at the bottom being squashed under the weight and ‘blowing’ the wrap’s seal.
• Regularly check bales for damage and re-seal with a UV protective tape.

http://www.bpsindustries.com/silagewrap.php

Little details make all the difference in baleage ( Reported )

by Kate Halstead
The author is with agriculture programs, Washington State University Snohomish County Extension.

Making bale silage is a combination of science and art.
Mastering the details will lead to the best possible forage.

A good tight bale of hay silage with the proper moisture content, carefully wrapped with at least four layers of plastic, and properly stored can remain palatable and nutritious for over two years.

There’s a lot more to making top-notch bale silage than simply achieving proper fermentation and harvesting at the proper maturity and moisture. At a Washington State University field day, WSU nutrient management specialist Joe Harrison and forage farmers Karl Hereth and Bruce Gregory shared their thoughts on what it takes to be successful when making bale silage or baleage.

While the science explains what conditions make for good and bad hay silage, it often doesn’t provide the practical details that can make for success or failure. It’s the farmers actually producing the hay silage who discover the tricks of the trade through trial and error.

Fertilizer, seeding, and pesticides. Adding 100 pounds of nitrogen per acre between first and second cuttings either with manure or fertilizer ensures grass pastures remain actively growing throughout the season. Most fields have weed pressures that build over time. While yearly spraying may be necessary for the worst, most can get by with a broadleaf herbicide spray every other year after first cutting. Reseeding with a straight orchardgrass every fourth year works well in western Washington to ensure maximum production.

Timing. Since sugars are highest in the afternoon, mowing at that time is ideal. Since that isn’t practical for larger acreages, the recommendation is to wait until the dew has dried off the grass in the morning to start mowing and finish as the sun goes down and before the evening dew starts to rise during the first hours of dusk.
Baling should take place as soon after cutting as possible. With temperatures above 65 degrees, it can often take place the day after cutting. When temperatures are higher, optimum moisture levels are often attained within 6 to 12 hours. When those conditions are prevalent, rule of thumb is to not cut more than you can bale and wrap before moisture levels drop too low for good hay silage.

Using inoculants. Addition of a bacterial inoculant can ensure a consistently good fermentation. Bacteria sometimes exist by the billions throughout a typical pasture and only need the right set of conditions to start the fermentation process inside a wrapped bale. However, there are occasions when an inoculant can improve the odds. Cuttings done later in the fall, when temperatures are cooler or after a frost, can be helped with the addition of an inoculant to ensure fermentation, even with the cooler temperatures.

Inoculants and acid-based additives can also help boost the shelf life of an opened bale by several days for smaller operations.
Rain. Keeping a constant ear to the weather forecasts is key to developing the timing needed to cut at optimum maturity, dry to the proper moisture level, bale, and wrap before a rain moves through.

If a soaking rain is predicted before the ideal moisture level is attained, it’s better to bale and wrap at a higher moisture level than to reduce nutritional levels through the rain leaching nutrients and going through another drying, tedding, and conditioning cycle. If the rain predicted is light, it will likely be better to wait before baling.

Weight. The trade-off in using large bales is weight. Depending on how high the moisture content was when the bales were wrapped, large bales can easily top the scales at well over a ton. Keeping the moisture content a little lower, less than 50 percent, can help make the larger bales a bit lighter while still providing a quality product. In addition, there will be more dry matter available per bale, helping keep consumption rates slower than with a wetter product.

Cutting knives. Some balers are set up with cutting knives set 3 to 4 inches apart. You can often remove every other one and double the distance between cuts without sacrificing quality or fermentation time. This also helps save fuel and time when baling. Since they should be sharpened after every cutting, using half the knives can mean each full set lasts twice as long before replacement.

Depending on how the bales are used, the longer fibers can help maintain bale integrity during handling after the wrap comes off. Bales made with all the knives in place break apart readily after the wrap is removed, sometimes even with the netting still in place.

Feeding. If you end up with some bales at a higher moisture content, above 65 to 70 percent, feed them soon after baling, usually within one to two months. Mix them at least 50-50 with drier bales, or there will be some weight loss. When used in grass-fed operations, be sure to introduce hay silage gradually to animals in the fall, and wean them slowly back onto fresh pasture in the spring.

Plastic disposal. Many regions now have collection services that will provide a dumpster to collect the used netting and bale wrap for recycling. Check with local waste disposal services or extension offices to find out what options exist in your area.

Try it, you might like it . . .
Like any other farming endeavor, making quality hay silage takes some science, some know-how, and a little weather luck. While making round bale silage may not be the ideal answer for every operation’s feed challenges, the rapid growth of the product for livestock producers large and small, coupled with the growing price of traditional feedstocks, makes it worth serious consideration.

Keys to Success When Harvesting Alfalfa as Baleage ( Reprinted )

Good baleage will be wrapped within 12 hours of baling and have a moisture level between 40 and 60 per cent, according to Ray Smith, Forage Extension Specialist at the University of Kentucky.

Alfalfa is an excellent forage for high-producing cows and universally considered one of the highest-quality forages. Cows efficiently use the high levels of protein, calcium and high-quality fiber in alfalfa for producing milk and meat. The palatability of alfalfa is high, especially when the leaves are maintained during harvest.

Typically, cows will eat more alfalfa than grass because the fiber content is usually lower in alfalfa. Harvesting alfalfa as baleage vs. hay greatly improves the chances maintaining high quality because there is less leaf loss and less loss of soluble carbohydrates.

The most important factor is harvesting high quality alfalfa baleage is harvesting at the right maturity stage. A common goal for high-quality alfalfa baleage is to cut in the mid- to late-bud stage, which results in >20 per cent CP, <30 per cent ADF and <40 per cent NDF.

A recent publication by Dr. Matthew Digman, Dr. Dan Undersander and colleagues “Field Practices to Hasten Drying of Hay and Silage” provides a good overview of new recommended field harvesting practices when making alfalfa baleage before baling and wrapping. One of the most important factors is cutting and laying in wide swaths to increase the drying rate as shown in Figure 1.

Ideally, lay the crop in a wide swath that covers at least 60 per cent of the cut area. This greatly enhances the initial 20 per cent water loss to reduce plant respiration and preserve sugars. Conditioning is also effective when swath density is low and weather conditions are favorable. Therefore, think about a mower-conditioner’s maximum swath width capability when making a purchase.

Figure 1. Representative Drying Curves for Narrow and Wide Swath Widths.

The University of Kentucky publication, “Baleage: Frequently Asked Questions” has recently been updated by Brandon Sears and colleagues and provides an excellent overview of the steps for good baleage production and harvest. The following pages contain excerpts of this publication. The complete publication can be found at the UK Forage Website under “Publications” and then under “Silage/Baleage.”

What Happens During the Baleage Ensiling Process?

If high-moisture forage (40-60 per cent ) is baled like normal hay, it will soon be rendered useless by explosive microbial activity. However, if this forage is baled and wrapped in plastic, anaerobic microorganisms will ferment some of the carbohydrates in the forage to lactic acid, which will inhibit the growth of detrimental microorganisms.

This is the same process that occusr when making corn silage or other types of silage in an upright or bunker silo. The advantage of making ensiling alfalfa as baleage over other methods is that farmers can often use existing machinery they have on the farm with the exception of the bale wrapper. Note: During the ensiling phase the lactic acid producing bacteria will consume some dry matter and digestible energy (mainly water soluble carbohydrates), but this loss is small compared to the dry matter losses that result from raking, baling, tedding, and storing round bales outside as hay.

What Should I Use to Mow?

Mower-conditioners are the most popular and easiest-to-use mowing implement for the baleage system. This is mainly due to faster wilting and evenly formed swaths. Also, using a mower-conditioner exposes more of the forage’s surface area to the microbes involved in fermentation and can result in a faster pH drop and better fermentation earlier in the ensiling process. However, other types of mowers can also be used successfully.

Can my Round Baler Handle High-Moisture Hay?

Most modern variable chamber balers (belt balers) are capable of baling wet forage into a dense package. However, special baleage models are recommended because they are specifically designed to bale wet forage—they have scrapers on the belts and rollers to prevent buildup of material, and they have heavy-duty bearings to help handle the increase in bale weight.

Several baler manufacturers offer “silage kits” which can be added to older balers that will enable them to handle baleage. Fixed chamber and variable chamber balers will both work well; however, variable chamber balers are much more popular because they allow the control of bale size and maintain uniform density in the bales. Fixed chamber balers are also capable of making dense bales but usually form only one bale size. In either case, it is important to drive slowly and maintain a high PTO speed.

When Should I Bale?

Baling at the proper moisture content is a key to success in producing baleage. Forage containing less than 40 per cent or over 65 per cent moisture should not be baled for baleage in order to avoid excessive molding or spoilage. Producing bales with too much moisture reduces forage quality, increases the chance of undesirable butyric acid fermentation, and reduces the amount of dry matter stored per storage unit—each of which greatly increases storage costs. Baling with inadequate moisture reduces fermentation and increases mold production, which greatly increase storage losses. Considering all factors, the optimum moisture for alfalfa baleage is in the 45-60 per cent range.

How should I make the Bales?

A slow ground speed during baling helps make tight, dense bales that are less likely to spoil. Plastic twine is recommended, but net-wrap or untreated sisal twine can be used successfully. Treated sisal twine should be avoided since the oils applied during the manufacture process often degrade the plastic film and can result in large storage losses. The most popular bale size is 4 feet wide and 4 to 5 feet in diameter. These bales will weigh 900-1300 lbs. (depending on forage type, bale density, and moisture level) and are best for handling and feeding.

How Soon Should I Wrap the Bales?

Delay between baling and wrapping lowers the quality of the bale because undesirable microbial activity and excessive heating occur while the bale is exposed to oxygen. In addition, waiting too long to wrap allows time for the bale to sag, and a sagging bale is difficult to wrap, uses more plastic film, and wastes time. Ideally, forage should be wrapped immediately after baling; however, research has shown that forage quality is maintained as long as it is wrapped within 12 hours of baling.

How Much Plastic Needs to be Applied?

Stretch-wrap plastic is usually one mil (0.001 in) thick and comes in rolls of 5,000 or 6,000 ft. The plastic is typically pre-stretched 50 to 70 per cent on the wrapper’s film dispensing unit to get the correct tension on the bale surface. Always ensure that the tension of the wrap (tacky side toward bale) is such that film is stretched uniformly on the bales.

At least four layers should be applied to each bale, but 6 layers provides even better insurance against spoilage. For an individual bale wrapper, the preferred method is the 2+2 system whereby two layers of wrap are applied during one rotation of the bale by a 50 per cent overlapping of successive layers.

Keep in mind that some types of wrappers dispense plastic differently than others. In-line wrappers can be purchased to dispense 4 rolls at a time rather than the standard 2 roll types. The 4-roll system increases wrapping speed. Some in-line wrappers also allow extra plastic to be applied at the joints between bales.

If this option is available, apply 2-4 extra layers at these joints. Use the high end of this range if bales lack uniformity or do not match up well at the joints. Do not apply too little plastic or oxygen will penetrate the bale and cause spoilage, mold growth, and feed losses. The plastic used in baleage does not create an airtight seal. Low-density polyethylene plastic such as that used in silage films is four times more permeable to carbon dioxide gas than it is to oxygen gas, allowing the bales to vent excess carbon dioxide gas as fermentation begins.

Should I be concerned with Botulism?

Clostridium botulinum is a bacterium that produces one of the most potent classes of toxins known to man. The spores of these bacteria are widespread in the environment (soils in particular) but are dormant. Under anaerobic conditions and with the right nutrients, the spores can germinate and grow, releasing toxins.

To minimize the risk of botulinum toxicosis from baleage, wrap bales at the correct moisture content (45-60 per cent ) and store them in areas that will reduce damage to the plastic from the environment or from critters. Type C botulism toxicity is usually associated with decomposing carcasses. This can be a problem if a dead animal is accidentally baled in the baleage or dry haymaking process.

Is Baleage Higher in Quality?

The feed value of the baled silage will be no better than the quality of the forage at the beginning, and can be worse if the bale was too wet and/or spoilage has occurred. As with conventionally harvested dry hay, quality is a function of forage maturity at harvest, handling during harvest, and storage. Relative to hay, however, the forage going in is higher in quality due to decreased harvest losses (eg – mainly leaf shatter), and the resulting baleage will not exhibit the same degree of losses during storage. Therefore, baleage will be higher in quality than comparable hay.

How Soon After Wrapping Can I Feed Baleage?

As mentioned earlier, baleage should be wrapped as soon as possible after baling to exclude oxygen and begin the fermentation process. Forage that is baled in the correct moisture range and wrapped with the correct amount of plastic will undergo the full fermentation process within 6 to 8 weeks (often in less than 4 weeks).

Fermentation conditions can vary due to forage maturity, temperature and bale moisture differences. Cool temperatures, mature forage, and insufficient forage moisture levels will reduce fermentation rate. It is advisable to wait at least 8 weeks after wrapping to begin feeding baleage bales. This will ensure that the baleage is stable and that it does not begin to deteriorate or heat when it is fed. This is especially important when attempting to feed in-line bales because feeding out these bales exposes the next bales to oxygen and spoilage risks.

How Long Can Baleage Be Stored Before Feeding?

The length of storage depends on forage moisture and maturity. Over-mature forage may develop some mold after 3 months. Forage that is baled too wet (>60 per cent moisture) may produce butyric acid during fermentation and cause feed value to be reduced after 3 months. If forages are baled at more than 60 per cent moisture, feed these before they are 3 months old.

At 30 per cent to 40 per cent moisture levels, feed value declines after 6 months. In general, forages baled at 40 per cent to 60 per cent moisture will maintain feed value for about 12 months as long as the integrity of the plastic is maintained. However, even where the forage was baled at the appropriate moisture level and the plastic has minimal holes, it is good practice to feed baleage bales within 9 months of when they were made.

How Do I Determine the Proper Moisture Content of My Forage?

1. “Dish rag” test. Take a handful of forage and wring it out like one would wring out a dishrag. If moisture can be expressed from the forage, it is generally above the 65 per cent moisture range.
2. Commercially available testers are an option for measuring forage moisture levels. However, accuracy may be a problem. At least three moisture readings should be obtained to create an average value. Commercial testing equipment can be costly ($200-$400 range).
3. Koster moisture testers are heated, forced-air dryers that are used in silage production to dry down the forage. It takes longer than a microwave moisture test.
4. The best method to use is the microwave moisture test. Detailed instructions are found in the following text:

Measuring the Moisture Content of Forage Using a Microwave Oven

1. Chop fresh forage into short lengths (< 1 inch) for ease of handling and uniform drying.
2. Weigh out at least 100 grams (3.5 ounces) of chopped forage.
3. Spread forage thinly on a microwave-safe dish and place into microwave. (A cup of water placed in the microwave beside the sample will help prevent the sample from igniting once dry.)
4. Heat for 1-2 minutes and reweigh. - If forage is not completely dry, shake and redistribute the sample, and repeat the heating cycle until the sample reaches a stable weight. (Microwaves vary considerably in drying capacity. It is better to dry for short intervals and reweigh until the last two weights are constant, than to overdry and run the risk of burning and damage to oven.) If charring occurs, use the previous weight.
5. Calculate moisture content using the following equation:

W1 W2 - W1 Content Moisture per cent ?

Where: W1 = weight of forage before heating

W2 = weights of forage after heating

Dry matter (DM) is the percentage of forage that is not water. DM equals 100 per cent minus the per cent Moisture Content.

Baleage Gains in Popularity as Method to Produce High-Quality Forage ( Posted by KUHN web )

Baleage continues to grow as an efficient method to produce high-quality forage. Not only is it a timelier method of harvesting forage than dry hay, it also results in lower harvest and storage losses.
Baleage is a relatively low-cost investment for smaller producers,” says Dr. Kevin Shinners, University of Wisconsin-Madison Ag Engineer. “If done successfully, it will result in lower losses, low spoilage and the forage is more readily available.”

Why baleage?
In comparison to dry hay, baleage requires less drying time, has lower losses at harvest during storage, produces a more uniform product, and requires no taxable structure. When compared to chopped silage, baled silage requires less expensive equipment, has a wider moisture range, allows for targeted feeding, requires no taxable structure, and is ideal for small operations. 

Moisture content
When making baleage, the forage is cut just as it would be for making hay, only it is baled at higher moisture content, rather than at 18-20% moisture. “My aim is to target 45-55% moisture,” states Shinners. 

Baling at the proper moisture content is the single most important variable. Making baleage at above 65% moisture content reduces the feed quality of the forage and the amount of dry matter stored per bag, greatly increasing storage cost. Baleage with inadequate moisture reduces fermentation and increases chances of mold production if the film integrity is compromised, greatly increasing storage losses.

Wrapping
Individually-wrapped bales occupy less area than tube-wrapped bales and are convenient for targeted feeding. They are also a marketable product and there is less aerobic loss at feedout.

When choosing a plastic to wrap baleage, look for blown low-density polyethylene that is about one mil (25 microns) thick. During the process of wrapping bales, the plastic is stretched in order to increase cling and form a tight seal; that’s why it’s essential to start out with the appropriate thickness. Additionally, it is important to always buy your plastic from a reputable source to assure high quality. The number of wraps you want to use greatly depends on the film quality, thickness and film density. “The No. 1 mistake producers make is not using enough layers of wrap,” says Shinners. Generally, he recommends five to eight layers of wrap (with 50% overlap). With lower moisture content, more layers of wrap are needed. He also suggests using more layers as needed when moisture decreases, maturity increases, or if the crop you are baling has sharp stems.

In addition, a timely wrapping process is required. Maintaining as short of an interval between baling and wrapping as possible is essential. A maximum of four hours is recommended to reduce crop exposure to air. This time window should be reduced even further in high temperatures.

Storage
After going to all of the hard work of producing a high quality crop, it’s imperative to properly store it to assure it retains that quality until the time you feed it. Moving bales to storage within two hours after wrapping is strongly recommended. Bale handling can cause film layers to relocate, thus breaking the seal. Bales should be stored in a well-drained area, away from animal activity, pests and rodents, and where you can maintain a watchful eye. Wrapped bales can be stacked, although Shinners recommends avoiding this practice when bales are higher in moisture, as this will cause the bales to “squish” and possibly break the plastic wrap seal. 

In order to gain the most value when making baleage, stick to these key tips:

Cutting
- Cut wide windrows
- Condition well to wilt quickly
- Don’t cut too low, dirt can create poor fermentation

Windrow formation
- Avoid raking soil into windrow

Baling
- Bale at 45-55% moisture
- Make uniform bale shape and size
- Avoid treated twine, it can damage film

Wrapping
- Use good quality plastic
- Stretch to 70-80% of original width
- Minimum 5 (high moisture) to 8 layers (low moisture)
- Avoid wet conditions
- Wrap close to storage site
- Wrap within 4 hours of baling

Handling
- As minimal as possible – avoid after 12 hours
- Use squeeze, avoid over pinching
- Making bales as large as you can handle greatly decreases storage, handling and plastic used

Storing
- Avoid woods, sharp stubble, poorly drained areas, and wildlife
- Store round bales on end – more plastic, less “squish”
- Avoid stacking at high moisture

The silage wrap specialist - BPS Industries Corp.

Silage wrap is a popular plastic film for wrapping the bale in the process of making best silage.

In China, BPS Industries Corp. is the professional and experienced manufacturer of silage protection products. Founded in 1998 with just one facility, BPS has grown into the largest manufacturer of silage protection film with two facilities in the city of Cangzhou and Dalian, and the affiliation company HTP in the city of Tianjin being the leading PET strapping producer in China, each designed to serve and surpass our customers’ expectations with its commitment to quality, innovation and expertise in flexible packaging with more than 23,000 tons of resin consumption annually. BPS exports from China to more than thirty countries throughout the world and has earned reputation in its field for excellent quality and timely delivery.

Products:

● Silage Protection Film : Silage Wrap , Silage Sheet , Silage bag ,Bale net wrap .

● Horticulture Film : Mulch film , Greenhouse film .
● Other Film: Geomembrane , Waste bale wrap , Building  film,V-process EVA Casting film

Careful selection of top quality raw materials as well as best process control, equipment guarantee the success of BeneAg silage wrap . "BeneAg" silage wrap comes with a 12-month guarantee against UV degradation, features high UV stabilization and provide an airtight seal when wrapping fodder. Now our "BeneAg" silage wrap suitable for "KUHN Balers ". "Mc-Hale" balers, "Lely Attis round bale wrappers", "CLASS" Square or round bale wrappers ," Vermeer" balers for wrapping round and square silage bales.