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

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Presentation on theme: " bpi.agri is a leading global supplier of innovative agricultural films: Silage Stretch Film Silage Sheets Silage Bags."— Presentation transcript:

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  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…..

6 Extrusion Methods

7 Single Layer Extrusion

8  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

9 A new 5 Multi Layer

10 Quality

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

12 Quality Holes and windows Tack tests Bale wrapping test Opacity

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

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

15 Product Overview

16 Silage Stretch Wrap Silage Sheets Silage Bags Product Range

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

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

26 Types of Bale Wrappers

27 New Generation Bale Wrappers

28 Bale Wrapper Maintenance

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

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

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%

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:

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

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

36 Bale Wrapper Calibration Film WidthNeck down 250mm190mm-210mm 360mm280mm-310mm 500mm380mm-410mm 750mm580mm-610mm Depending on % stretch and temperature

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.

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

46 Tack Build-up on PSU Rollers

47 Aquaplaning

48 Resolving Aquaplaning

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

50 Bales Splitting Not enough film – uneven application

51 Worn Belts causing uneven overlap

52 Roll Identification

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

54 Thank you for your attention Any questions?


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