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Editors of The World Book Encyclopedia once stated that if all the wheat acreage in the United States and Canada were consolidated it would create a 60 million acre field that would be larger than the combined states of Illinois, Indiana, Iowa and Missouri. And considering that a good reaper using a hand sickle could cut an acre per day, 1.5 million reapers couldn’t harvest the crop in less than 40 days.
But unlike grain producers, whose combines can operate with almost complete efficiency, hay producers are still looking for ways to cut costly losses that occur beyond the dry round bale. For many, this involves getting a feel for hay ensiling, using a new generation of bale wrapping machines.
The efficiency problem
Forage experts emphasize that the keys to determining the economic feasibility of a bale wrapper is determining how much its use will reduce waste and enhance nutritional values. These experts point out that losses begin a day after a forage’s optimal mowing date.
University of Missouri Extension Beef Specialist Eldon Cole, who has gained respect for his forage interest and expertise, says fertilized fescue can produce hay with protein and total digestible nutrient levels of 15 percent and 65 percent, respectively, if cut around May 10. "But these levels can drop to 5 percent and 50 percent if harvest is delayed until June."
A Texas A&M University computer program shows that the loss of each one percentage point of protein and TDN per ton can cost over $3 and over 50 cents, respectively. This is a potential loss of over $37 per ton, using Mr. Cole’s figures.
Raymond Huhnke, extension agricultural engineer at Oklahoma State University has quantitated dry matter losses of up to 15 percent in the mowing-raking-baling process. "This occurs as the result of plant respiration and machine losses. These field losses can be greatly reduced if hay is put up as baleage," he states.
David Bade, extension forage specialist at Texas A&M University, says dry matter losses can run between 5 percent and 50 percent in unprotected bales stored outside. "The actual amount depends on the kind of hay, the tightness of the bale, how it is stored and the amount of rainfall. Feeding losses may be only 3 to 5 percent in rolled-out hay fed in the right amount. Losses from hay fed in bale rings may be as little as 5 percent for good quality hay that the cattle don’t pick over. Losses of up to 30 percent can occur in intact bales fed without protection."
In combination, these dry matter losses can be costly. At 84 cents per each percentage loss, the total loss of 33 points of dry matter shown in the dry-bale column of Table 2 would increase the cost of $50-per-ton hay to $87.80 per ton.

For a larger version of this table press here

The baleage option

  

Most cattlemen have yet to put a pencil to bale wrapping because little has been published about the concept, and its economic feasibility is not easy to figure from scratch. Each operation has its own set of harvesting, storage and feeding circumstances. Yet, an analysis can be well worth the effort.

"The main obstacle is that it is easier for cattlemen to see the cost than the benefits," says Wayne Schnelle, a principal in S&H Farm Supply, Lockwood, Mo. "Hay can be cut when nutritional values are optimal. There is no extended curing period in early-season weather. About the only loss of dry matter occurs during the ensiling process (oxidation loss). As a wet product, little waste occurs when the product is fed from a hay ring and cattle literally eat baleage into the ground when it is unrolled," Mr. Schnelle explains.

"The concept doesn’t replace the round baler and its attendant equipment; it adds a machine," he adds. "If an operator has justified the cost of basic haying equipment mower, rake and round baler it can be surprising how justifiable it is to add a $16,500 wrapper."

As a rule of thumb, a bale wrapper can be economically feasible for anyone who can justify the purchase of basic haying equipment a mower, rake and round baler. This is true if there is a sufficient problem with nutrient and storage waste (see Table 2 assumptions).

A Texas A&M computer analyzer shows that it is as economical to own a round bale system as it is to hire a custom operator if your dry-hay requirement is 235 tons or more per year. This is the equivalent of haying 157 acres of grassland that produces 1.5 tons of dry hay per acre with haying equipment valued at $23,500 powered by a $9,000 tractor.
These economics put a dry baling system within the reach of a cow-calf producer feeding a 157-head cowherd 1.5 tons of hay per year as harvested.

An analyzer developed with the aid of James McGrann, a Texas A&M economist, shows that herd owners meeting the requirements for dry hay equipment can justify adding a $16,500 bale wrapper on 289 tons of ensiled hay. Considering the greater moisture content of the ensiled hay, this amount is the equivalent of 170 tons of dry hay and is an amount that is well within the acreage requirement for justifying the base haying system (see tables).

Mr. Schnelle points out that machine rental is becoming an option for some cattlemen. "Renting costs about $6 per bale, including wrapping material," he says. "Sometimes the machines are never returned because users recognize their value and find that they are easy to use."
And so, technology marches on in the hay industry. The role of the square baler is waning. Will the bale wrapper now join the round baler to create the haying system of the future the least-waste system that will fulfill the cow producer’s quest for convenience and efficiency? The possibility exists for operators with the right combination of herd size and hay waste.

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