This new system involves replacing the roll of netwrap in the baler with a roll of plastic film that’s different than the normal bale wrapping film. This new plastic film has to be slightly stronger with durable clingfilm properties to give a stronger hold on the bale. It has to cover and protect the bale and its edges in the bale chamber and then either release it to the ground intact for wrapping later or transport it to the wrapping section of a combination baler and wrapper. This new plastic is typically 20 microns thick; thinner than standard wrapping plastic.

It has better stretching and clinging properties to ensure that the bales keep their round shape before wrapping. It has to give a minimum of three layers of plastic on the bale, which can be followed by a normal four layers of the usual wrap.

The big advantage of using this system is an opportunity to save on wrapping costs and also to save time at bale feeding time. At feeding there is only on plastic material to be removed.

ADVERTISEMENT

There are differing views among baler makers on the use of the system. Some believe that the system has a lot to offer while others believe that it will add costs to bale wrapping as the replacement netwrap film could be more expensive than netwrap in terms of bales wrapped per roll.

The opportunity to save on wrapping costs is due to using film on the bale instead of netwrap which will mean that farmers can have a seven layer wrap on the bale in place of six layers plus netwrap. This is achieved by a three plus four system with three layers of netwrap replacement film followed by four layers of the normal wrap.

There will be a number of machines in action with the system this season. The baler kits must be able to use both netwrap and netwrap replacement film with little adjustment to be successful. McHale, Claas, Krone, New Holland and Welger are all working on baler kits to take both products. YouTube followers will be able to see where a New Zealand farmer has modified a Krone Comprima to apply the netwrap replacement film.

McHales have completed a number of trials of the system. They have produced a small number of prototype Fusion 3 combination balers fitted with the film dispenser unit for use in Ireland this season.

Feeding the plastic film with its heavier level of stickiness or tack into the bale chamber has been one of the challenges. McHales accept that it is a different challenge applying plastic to the bale in the chamber compared to applying netwrap.

McHales are developing new software to allow the operator to apply replacement wrap film using the baler control box in the tractor cab. This allows for automatic adjustment of the tension differences needed for the new film compared with netwrap.

There are temperature, humidity and crop factors to be considered.

For McHales, applying film in the chamber instead of netwrap will require a new machine, not a kit, and it looks like retrofitting will not be an option.

New Holland is offering the kit as a standard feature on the Orkel built range of combination baler and wrapper machines. The unit is fitted to the 125 and 135 model balers which are new to the range for this season.

It is expected that New Holland will demonstrate at least one of these machines in Ireland this season.

Will it cost more?

Some baler manufacturers claim that the new netwrap replacement film will cost about €1 per bale extra. There is an opportunity for a netwrap cost saving for those farmers who have been using netwrap with six layers of bale wrap.

The figures will be debated as some farmers and contractors are applying up to three layers of netwrap followed by up to six layers of wrapping film. With a new system using even four layers netwrap replacement film followed by four layers of normal wrap, the cost differences will be less if at all. Some will argue that this approach will give a greater number of layers and better protection of bales.

The Baletite net replacement film costs €175 per roll and will be sufficient to cover 145 standard silage bales, according to Sean O’Connor of suppliers Irish Polythene Agri. This equates to about €1.40 per bale.

Using four layers of wrap instead of six, which he claims 20% of farmers are currently using, will mean a cost of €3.63 per bale which drops to €2.58 per bale if four layers are used. Adding this to the cost of the new Baletite film at €1.40 per bale, means a total cost of €3.98 per bale, which he claims to be more cost effective than netwrap and six layers of bale wrap, which he claims costs €4.18 per bale.

Film choices

Film manufacturers BPI, who produce the Silotite range, have developed a new Film&Film System using a product called Baletite available from Irish Polythene Agri. They claim it delivers superior quality silage through greater bale density and an enhanced oxygen barrier. The Film&Film system involves the combined use of a wide polythene film (commonly known as ‘Mantle’ film) alongside the next generation of Pro Technology bale wrap. Mantle film replaces the traditional netwrap used to bind crops into a bale format.

They claim that Film&Film System bales have greater protection around the bale circumference thanks to the extra film layers.

Sean O’Connor, general manager at Irish Polythene Agri said that early adopters of this new system in Ireland have been impressed by the mould free bales they unwrapped in recent months to feed-out. Film&Film System bales also have greater protection around the bale circumference thanks to the extra film layers.

He claims that the Baletite has given a tighter bale that is slightly smaller in circumference than a net wrapped bale. This he claims resulted in 1 to 2 bales wrapped per roll of the standard film that completed the four layer wrap that followed.

Volac supplies the Trioplast wrapping plastic and the company confirms that the system of using replacement wrap film in place of netwrap is more widely used in Sweden where the Trioplast is manufactured.

The Volac product called Bale Compression Film is available in Ireland this season but supplies are limited. This roll is 2000 metres long, so it is shorter than netwrap to cope with the additional weight.