1. bpi.agri is a leading global supplier of innovative agricultural films:
Silage Stretch Film
Silage Sheets
Silage Bags

2. bpi film is used to wrap more than 50 million bales in over 50 countries every year

3. Operations Overview

4. Leading Production Facilities

5. How it all began…..
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

6. Extrusion Methods

7. Single Layer Extrusion7

8. A Multi Layer Extruder
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 8

9. A new 5 Multi Layer 9

10. Quality

11. Quality
Throughout the production process we evaluate the following product properties and tests:
Dart drop test
Weather testing
Winding tension
Tear strength
Tensile Test 11

12. Quality
Holes and windows
Tack tests
Bale wrapping test
Opacity 12

13. Quality Accreditations
BS EN ISO 9001 Quality Assurance Standard
14001 Environmental Standard
SP (01) (02) (03) (04) Swedish Quality Standards 13

14. Development Partners Working closely with Dow Chemicals
Undertakes research initiatives with IBERS
Universities
Complies with rigorous Swedish SP Standard 14

15. Product Overview

16. Product Range
Silage Stretch Wrap
Silage Sheets
Silage Bags

17. Product Overview Silage Stretch Wrap Colours: Black White Green
Silage Stretch Wrap Widths:
250mm
360mm
500mm
750mm

18. World’s first multi layer balewrap
Over 20 years experience
Global market leader
Sold in 58 countries across 6 continents

19. 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

20. Investment Programme

21. Agricultural Films Investment Programme
Our agricultural films investment programme has seen the Group:
Install 5 silage film manufacturing lines since 2000 including 2 lines at Leominster in 2008
Install 3 pre-stretch lines since 2006 including 1 at Leominster in 2008
Install a new wide width silage sheet line in 2005
Acquire AT Films – the leading North American silage sheet and bag manufacturer in 2007

22. Leominster Agricultural Film Investments
Our two new lines and pre-stretch machine at Leominster represent a major investment in excess of €10 million in our agricultural films division
This investment reflects BPI’s long term commitment to the market
We now have:
A new extrusion hall
Two new multi-layer extrusion lines
A fully automated packing station
A pre-stretch machine
Extensive new warehousing facilities
Improved loading & despatch area

23. Leominster Investment Programme
Benefits of the new investment:
- Reinforces our long term commitment to the balewrapping market and the Leominster site
- 40% increase in balewrapping production capacity
- Opportunity to increase pre season stock build
- Quicker turnaround times to meet swings in demand
- Opportunity to develop the next generation of films
- Further enhancement of the company’s excellent quality record and customer service standards

24. Wrapping Process

25. 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 25

26. Types of Bale Wrappers 26

27. New Generation Bale Wrappers27

28. Bale Wrapper Maintenance28

29. 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 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

30. Bale Wrapper Calibration
Align film with bale centre to achieve correct overlap 30

31. 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 31

32. 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% 32

33. 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: 33

34. 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 34

35. 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 35

36. Bale Wrapper Calibration
Film Width
Neck down
250mm
190mm-210mm
360mm
280mm-310mm
500mm
380mm-410mm
750mm
580mm-610mm
Depending on % stretch and temperature 36

37. 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. 37

38. 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

39. 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

40. Handle Bales with Care

41. Potential Balewrapping Issues

42. Common Problems Operator Error Spiral Tearing Aquaplaning
Film Breaking
Holes in film on bales
Film splitting on bales
Uneven overlap on bales
Rodent damage

43. Spiral Tearing

44. Film Striations

45. Air Bubbles 45

46. Tack Build-up on PSU Rollers

47. Aquaplaning

48. Resolving Aquaplaning

49. Holes in Film on Bales Bird Damage Bramble Damage Handling Damage
Rodent Damage

50. Not enough film – uneven application
Bales Splitting
Not enough film – uneven application

51. Worn Belts causing uneven overlap

52. Roll Identification 52

53. 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 53

54. Thank you for your attention
Any questions?