Little known to our dealers and for many of our employees is the fact that our large square baler, the 2170XD and now the 2270XD, is recognized as the “King of Collection” for the baling of corn stover and wheat straw for the fledgling cellulosic ethanol industry. For over 5 years, AGCO has been working with both leading industry and university associates to develop an economical biomass feedstock supply chain. Now our balers are the centerpiece of the supply chain critical to the success of the first 3 major projects for the industry. These three projects are Abengoa’s Hugoton, KS project; Dupont’s Nevada, IA project; and POET/DSM’s project in Emmetsburg, IA. Each one is making ethanol from corn stover. Taken together these projects will require over 1,000,000 dry tons of material or roughly 1.8 million bales of which over 1.5 million will be large squares. With the corn harvest lasting only 6-8 weeks, to say there is intense activity for the baling of corn stover is a huge understatement.
Whether collecting this material for his or her self or having a professional harvester do it, this is a source of additional income for our farmers. Data has also shown an additional benefit resulting from this undertaking of residue management. With corn yields continually increasing, our farmers are producing rising amounts of corn stover as well. In fact so much residue is available after harvest that leaving it all on the field is not providing the same benefit it has in the past. The evidence is clear that removing some of the stover results in better yields in a corn on corn rotation. Uniformity of seed placement and depth, faster soil warming, less nitrogen fixing and less disease all help increase yields from 5-10%; this with the added benefit of less tilling.
Last year, during the 2013 corn harvest we had over 100 of our 2170’s and 2170XD’s at work making over 1,000,000 bales of corn stover for the ethanol industry. This amounted to over 90% of the large square balers working in this market. AGCO is working through product development to continue to improve our large square baler to support this dynamic new industry and our farmers. Better densities; data acquisition, management and evaluation; all helping to improve the operators of our equipment; and producing the most reliable and efficient large square baler in the market. This makes it easy to understand why our large square baler is considered the “King of Collection”.
If you would like to learn more about AGCO’s Biomass Solutions, please visit: www.bit.ly/AGCOBiomass.
If not in its infancy, biomass farming is perhaps still toddling along. Yet, most indicators point to a significant increase in production and an additional source of revenue for farmers, as well as a variety of other benefits, depending on the crop being grown.
Signs point to a number of infrastructure, process and equipment enhancements that will make the harvesting, transportation and storage of biomass much more efficient in the next few years, if not sooner.
For starters, consider the harvesting of corn stover, which in many areas of the country can increase corn yields for the following year. Also, perennial grasses such as miscanthus and switchgrass can be grown on marginal land, require little in the way of inputs, and offer a number of environmental benefits, such as helping to filter runoff and prevent erosion.
Among such biomass-producing crops, stover already has a foothold. It’s readily available in many parts of the Corn Belt, where a partial harvest does help yields.
Now farmers and the biofuels industry are looking ahead at increased production of all things biomass, including the crops mentioned above, as well as energy sorghum, woody biomass and more. The U.S Department of Energy predicts total crop- and pastureland planted in bioenergy crops will increase from less than 10 million acres today to between 60 and 80 million acres over the next 15 years.
As a result of this increased demand, new processes and technologies are in development to help make the gathering and transport of biomass, particularly stover, more efficient and profitable for the farmer. Especially promising is single-pass harvesting, which promises the operator considerable time and fuel savings over other methods currently in use.
“AGCO has a unique solution for single-pass harvesting equipment with their new series of combines that are single-pass compatible,” says Dr. Matt Darr, assistant professor of Agricultural & Biosystems Engineering at Iowa State University. “AGCO is also a leader in the industry with single-pass baling products to provide producers and large energy companies the opportunity to make single-pass harvesting a reality within a supply chain.”
The technology in Hesston® by Massey Ferguson balers is ready-made to handle stover, as well as other biomass crops. Already, the Hesston 2170XD large square baler has earned its stripes for how densely it can pack the bulky crops, says David Ibbetson, a Kansas-based custom baler who uses two 2170XD balers to bundle some 15,000 bales each year in Iowa. He also uses Hesston round balers to bundle another 1,500-plus bales closer to his home in Yates Center.
Several other pieces of equipment that will aid in the harvesting of residue are now in the pipeline at AGCO. One such tool is a corn header that can harvest upwards of 150% higher volumes of corn and MOG. Another is a receiver chute that’s attached to the front of the baler and allows it to take in MOG without it being deposited on the ground before baling. “By having the baler accept the residue directly,” explains Maynard Herron, AGCO’s engineering manager at its Hesston, Kan., plant, “you cut in half the amount of ash in the bale. Those cleaner bales, of course, are more valuable and make this approach to stover more profitable to the farmer.”
Watch a video of Iowa State’s Dr. Matt Darr explaining when harvesting corn stover can increase yields, save money and time, and generate revenue at http://www.myfarmlife.com/crops/the-case-for-stover/.
Continue the conversation: Do you harvest stover? If so, have you seen a benefit on your farm?
If you would like to learn more about AGCO’s Biomass Solutions, please visit: www.bit.ly/AGCOBiomass.
Downtime is costly for any producer, but it’s even worse for commercial operators who depend on quality hay for their livelihood. That’s one reason Larry Krepline goes through his two Hesston big square balers and Hesston windrower every fall with the help of Gruett’s Inc., his Massey Ferguson dealer in Potter, Wisc. That is, after he totally cleans each machine at the end of the season with compressed air and/or a power washer.
“One of their technicians actually comes out here to the farm and we go through the full checklist on each machine,” Krepline says. “After that, my crew and I will make most of the repairs ourselves based on the recommendations. At the very least, we’ll change all the fluids, including the oil in the cutterbed, and replace all the disc header knives, along with the bolts and bushings. I don’t need any of them breaking during the season.”
With three windrowers, two big square balers and ten 3-twine balers, Mark Atkinson, owner of Atkinson Hay Company in Dixon, Calif., has a big maintenance project each winter, too. However, by the time he and his crew finish, Atkinson says every machine they own has been restored to like-new condition.
“In fact, our dealer usually has somebody waiting for a machine when we trade it,” he adds. “We literally take every machine apart and rebuild it, replacing any part that we have doubts about. If there’s any question about whether it will make it through the next hay season, we replace it,” he adds, noting that replacement parts include everything from knotter bill hooks to bale chamber side plates. “Downtime is too expensive to risk it.”
Another tip, this one from Dean Morrell, product marketing manager for Hesston by Massey Ferguson hay products: “Months down the road it can be hard to remember that noise you wanted to check out before next season. By writing it down, when you notice what might be a problem, you have a big head start on maintenance that will leave your equipment in top condition, ready for another productive season.”
For detailed checklists for hay equipment maintenance, including a video from our own Dean Morrell, product marketing manager for Hesston® by Massey Ferguson hay products, see http://www.myfarmlife.com/advantage/hay-equipment-maintenance-checklists/.
For 65 years, this rural burg on the eastern edge of the Great Prairie has been home to a brand that shares its name and is fertile ground for the development of game-changing agricultural machines.
During the Dust Bowl years, a “hill” on an otherwise flat stretch of the Great Prairie was often a piece of farm machinery buried by the era’s black blizzards of blowing topsoil, then deserted due to a hole in the social fabric called the Great Depression. Folks did what they could to survive, and a young Kansan named Lyle Yost helped make ends meet by scouring the countryside around his family’s farm for these mounds of dirt and steel.
“He was as young as 14,” says his daughter Susan, “and as soon as Dad learned how to drive, he would take the truck out into the countryside and look for [abandoned] farm equipment.” Yost, who passed away last year, would excavate what he found and bring it home, where he and his father would use it for spare parts or repair it for sale. “Not only did Dad learn how to build and rebuild [farm equipment], but he got acquainted with farmers,” Susan says. “He learned from them and found out what they needed. The idea of Hesston Corp. was planted when he was a teenager. I don’t think he knew the direction, but he knew that he had a calling, which was to help farmers.”
That direction became clear years later when he took on a problem that afflicted practically every farmer and harvester who owned a combine back in the day. Unloading just took too much time. Yost’s contemporaries used shovels and gravity to get the grain out of the bin, losing valuable time to get the grain up and out of harm’s way.
Yost, however, had an idea for a better way to move that grain, and after a particularly difficult harvest in 1947 and with memories of Dust Bowl storms still fresh, he and blacksmith Adin Holdeman went to work developing his unloading auger design. They made five of them in about a month, Susan recalls, and sent Yost’s cousin Earl Burner out to sell them. “He got back in 3 hours and said he needed 10 more.”
When they returned to the harvest the next summer using their new machine, others witnessed the speed at which the augers unloaded grain, and orders began arriving from as far as Texas and North Dakota. Buoyed by that success, the three men set up an assembly line near their homes in Hesston, and Hesston Manufacturing was born.
More than a half-century later, Yost’s focus on farmer-oriented solutions lives on today. Still located in the small, rural town where it all started, the Hesston facility has gone on to develop some of the most productive machines in agriculture, with the harvesting equipment made there now being sold worldwide.
Read the full story at http://www.myfarmlife.com/advantage/uncovering-the-hesston-story/.
The beads of perspiration forming on Monte Innes’ forehead are swelling but not yet heavy enough to succumb to gravity. It is early August, a sunny 80 degrees Fahrenheit, and he’s leaning against a large square bale amid a 480-acre strip of land along the Ohio Creek in south-central Colorado.
“This is a real harsh area to work in,” says Monte, 43, who cuts and bales hay on nearly 6,000 acres tucked piecemeal into high, arid mountain valleys up to an hour-and-a-half apart. “The cold can settle into this valley here in the winter and it’ll be 35 below for days.
“Every valley has its own microclimate,” he continues, “and in the spring and summer, rainfall can vary tremendously from one hay field to the next all within a few miles of each other. You just kind of roll with the punches.”
On this particular day, however, the Ohio Creek Valley resembles paradise. Mountains rise up around us on three sides. Most grand are the Anthracites directly to the north.
Acres worth of grass have already been cut and laid down by Monte. In an adjacent field, his wife Julie is running the baler, dropping large rectangular blocks in her wake. Across the valley lush grasses—timothy, red top, brome and clover—fed by recent, unusually heavy rains, beg to be harvested.
Monte and Julie picked up an additional 900 acres worth of hay to farm this year, in large part because of their new Hesston® by Massey Ferguson WR9770 windrower. Their new customer had seen the clean, close cut the Inneses had achieved on a nearby property and realized his existing custom balers were leaving money in the fields.
“This is the third RazorBar disc header we’ve had, and we wouldn’t own anything else,” Monte says. “We get all the hay. It is a clean cut an inch from the ground.”
He also appreciates the speed with which the machine can travel. “It is awesome traveling down the road at 20 mph from one field to another,” he continues, noting how important that speed is when you’re working numerous scattered fields.
The windrower is quick in the field, too. “Today I cut 180 acres in six-and-a-half hours,” he says, “and I couldn’t have done that with any other machine.”
Their dealer, Luke Sharpe, of Sharpe Equipment and Irrigation in Salida, says that the care and ability of the operators also play a role in how well the couple do their jobs. “Monte and Julie work their butts off, and their hay quality is phenomenal,” he says.
Their new Hesston by Massey Ferguson 2170 XD baler, which is being pulled by an MF6495 tractor, is making and saving them money, too. “Our new baler is a home run for us,” Monte says.
The 2170 XD produces bales that are denser, heavier. Because of that, they can now get 26 to 27 tons of hay on a semi trailer truck for shipment, rather than 22 tons.
“That saves us about 50 loads per season,” says Monte, “which saves us about $25,000 in shipping costs.”
As for the tractor, “it is phenomenal on fuel running the baler,” Monte says. “I kept calling the dealership saying, ‘I think the fuel gauge is wrong.’
“It wasn’t broke; it was just getting that much better fuel economy.”