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bpi.agri is a leading global supplier of innovative agricultural films: Silage Stretch Film Silage Sheets Silage Bags. bpi film is used to wrap more than 50 million bales in over 50 countries every year . Operations Overview. Leading Production Facilities. How it all began…. - PowerPoint PPT Presentation
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bpi.agri is a leading global supplier of innovative agricultural films:• Silage Stretch Film• Silage Sheets• Silage Bags
bpi film is used to wrap more than 50 million bales in over 50 countries every year
Operations Overview
Leading Production Facilities
In the early days of bale wrapping most bale wrap was made up of a single layer construction
Then in 1986 BPI pioneered “co-extrusion” which was to change the future of the manufacturing of silage stretch wrap
How it all began…..
Extrusion Methods
Single Layer Extrusion
A co-extruder works on the same principle as the mono layer machine, but a minimum of three times over to form a multi layer sheet
A Multi Layer Extruder
A new 5 Multi Layer
Quality
Quality• Throughout the production
process we evaluate the following product properties and tests:• Dart drop test • Weather testing • Winding tension • Tear strength• Tensile Test
Quality
• Holes and windows • Tack tests • Bale wrapping test • Opacity
• BS EN ISO 9001 Quality Assurance Standard
• 14001 Environmental Standard
• SP (01) (02) (03) (04) Swedish Quality Standards
Quality Accreditations
Development Partners– Working closely with Dow
Chemicals
– Undertakes research initiatives with IBERS
– Universities
– Complies with rigorous Swedish SP Standard
Product Overview
• Silage Stretch Wrap
• Silage Sheets
• Silage Bags
Product Range
Product Overview
• Silage Stretch Wrap Widths:– 250mm– 360mm– 500mm– 750mm
• Silage Stretch Wrap Colours:– Black– White– Green
• World’s first multi layer balewrap
• Over 20 years experience
• Global market leader• Sold in 58 countries
across 6 continents
• Multi-layer construction for superior strength
• High tack level eliminates long tails
• Superior tack level for excellent sealing
• Uniform stretch with no striation weakness
• UV sunlight protection for all climates
Wrapping Process
Crop Preparation• The crop must be suitable for making good
silage/haylage• It should be at the correct growth stage• Over-mature stemmy crops do not produce good
results!• Choose a favourable period of weather • Produce a full-width swath of oblong section and
uniform depth and density• Aim for 40-50% dry matter (DM) at baling, and up to
60% for haylage• Do not wrap bales which exceed 60% DM• Make well-shaped bales of uniformly high density• Avoid soil contamination
Types of Bale Wrappers
New Generation Bale Wrappers
Bale Wrapper Maintenance
Bale Wrapper Preparation• Set wrapper and install film
as per manufacturers’ instructions
• Follow bpi.agri’s Ten Top Tips of Bale Wrapping available to download from www.bpiagri.com. Hard copies always available from your bpi.agri contacts
• Better Balewrapping DVD also covers this subject and is also available from your bpi.agri contacts
Bale Wrapper Calibration
Align film with bale centre to achieve correct overlap
Bale Wrapper Calibration• 25 mu film should be
applied at 55-70% stretch on round bales and 55-60% on square bales, depending on climatic conditions
• Two marks applied 10 cm apart on the reel should then be 15.5 – 17cm apart when on the bale
Bale Wrapper Calibration• How to calculate film usage• The number of bales that can be wrapped from a
single roll of bale wrap can be accurately calculated, provided the following points are adhered to:
• THE BALE SIZE IS 1.2m X 1.2m AND OF UNIFORM SHAPE
• THE WRAPPER IS CALIBRATED FOR THE CORRECT NUMBER OF TURNS
• 4 film layers 16 turns (750mm) 6 film layers 24 turns (750mm)
• THE FILM IS ACCURATELY AND CORRECTLY STRETCHED TO 70%
Bale Wrapper Calibration• If all the parameters are correct (bale size,
film stretch of 70% and correct number of bale revolutions) then the following figures will always be achieved.
• Any variation to the above parameters will cause numbers to differ.
• Given a standard bale size of 1.2m x 1.2m, applying film at 70% stretch using the correct number of turns for the film width used 16 turns for 750mm for 4 layers of film) the calculations are as follows:
Bale Wrapper Calibration• A = BALE CIRCUMFERENCE (sum length of all
four sides of the bale) B = TURNS OF THE BALE C = FILM LENGTH AFTER STRETCH (film roll length plus 70%)
• Multiply A by B and divide into C.• 2,550m
(1,500m +70%)• 33.2 bales per roll
Bale Wrapper Calibration• If however your stretch % is only 55 % then • 750mm• 2325 m
(1,500m +55% )• 30.2 bale per roll• • CURRENTLY AT 55% STRETCH WHICH MOST
BALERS ARE SET AT ARE ALREADY ACHEIVING 3 MORE BALES PER ROLL WITH SILOTITE! SO WHEN CORRECTLY SET UP SILOTITE SHOULD BE R 1,50- R 3 CHEAPER PER BALE THAN ANY OTHER FODDEWRAP ON THE MARKET EVEN THOUGH IT IS MORE EXPENSIVE PER ROLL
Bale Wrapper Calibration
Film Width
Neck down
250mm 190mm-210mm
360mm 280mm-310mm
500mm 380mm-410mm
750mm 580mm-610mmDepending on % stretch and
temperature
Bale Wrapper Calibration• Count number of turns to completely
cover bale in film.• Add 1 extra and double this figure for
4 layers.• Add 1 extra and triple this figure for
6 layers.• E.g. 8 turns to completely cover + 1
= 9 x 2 = 18 turns for 4 layers.
Essential Bale Wrap Properties During The Wrapping Process
• Must have even stretch• Resistance to tear during
elongation• Correct tack level• Not over elastic so that
film is over stretched and too thin when on bale
Essential Bale Wrap Properties After The Wrapping Process
• Needs to have a “memory” and retain elasticity
• UV protection to stop degradation• Strength properties to resist puncturing and
tearing of film as well as impact damage• Adhesive properties to maintain long term
sealing• Low oxygen permeability
Handle Bales with Care
Potential Balewrapping Issues
Common Problems• Operator Error• Spiral Tearing• Aquaplaning• Film Breaking• Holes in film on bales• Film splitting on bales• Uneven overlap on bales• Rodent damage
Spiral Tearing
Film Striations
Air Bubbles
Tack Build-up on PSU Rollers
Aquaplaning
Resolving Aquaplaning
Holes in Film on Bales
Rodent Damage Handling Damage
Bramble DamageBird Damage
Bales Splitting
Not enough film – uneven application
Worn Belts causing uneven overlap
Roll Identification
Summary• Always handle rolls of film with care
• Load film in the correct way
• Keep PSU rollers clean from tack build up
• Align film with centre of bale
• Calibrate number of turns required
• Check film for correct stretch & neck down
• Ensure wrapper is properly maintained for optimum film application
Thank you for your attention
Any questions?