What is a baler-wrapper combination?
A baler-wrapper combination or combi baler is a round baler and a bale wrapper in one. First the crop is compressed into consistent and dense bales in the bale chamber. Once ready, the bale is bound with net or film. Next, the bale is transferred onto the wrapping table and is wrapped with stretch film. The baler can have a fixed chamber or a variable chamber. A third type is the variable high-density (HD) bale chamber.
Fixed chamber baler-wrapper
A fixed chamber baler-wrapper produces round bales with one set bale size or diameter. A fixed bale chamber is constructed from powered steel rollers that form a round bale while rotating. It is a reliable concept for easily making a nice bale. Even in challenging conditions, such as short and wet crops, a fixed chamber baler will still produce a good bale.
While filling the bale chamber, the driver can use the full capacity of the intake. Compaction of the crop is done by the machine only from the moment the bale chamber is almost full. After binding, the bale is quickly ejected to start the new bale again. As a result, the capacity of a fixed chamber baler wrapper combination is at a high level. Due to its low-maintenance and reliability, user-friendliness and high capacity, a fixed chamber baler excels at a low cost per bale. However, take into account that with a fixed chamber baler bale diameter cannot be varied and, compared to a variable chamber baler, it is more difficult to get good bale density in drier crops such as hay and straw. Advantages:
· User-friendly concept; easy to make a good bale
· Hugely reliable concept with fixed rolls
· Good cost per bale
· Low power requirement
· High capacity
· Very suitable for short and wet autumn crops
· Bale diameter cannot be varied
· Less suitable for drier crops such as hay and straw compared to a variable bale chamber
Variable chamber baler-wrapper
A variable bale chamber consists of a combination of fixed rollers and adjustable belts that can grow the chamber from small to large. As a result, a bale is compacted from the core to the desired diameter. The variable concept is very suitable for turning dry crops such as hay and straw into a nice bale with a high density.
A variable baler excels above all in versatility. Baling silage in the morning with a 1.3 meter diameter, baling smaller bales of hay in the afternoon and making large bales of straw in the evening. It can all be done with the same machine.Advantages:
· Bale size can be varied, from small bales for horses, for example, to large straw bales
· A larger bale size can reduce costs
· A well-compressed bale right down to the last bale
· Density can be varied from core to outer layer
· Better suited to dry crops such as hay and straw
· Good cost price per bale
· Low power requirement
· Driver needs a little more experience to make perfect bales
· Less suitable in extremely wet autumn crops
Variable high-density (HD) baler-wrapper
This baler combines the advantages of a fixed and variable bale chamber in one machine. It can bale extremely wet crops like a fixed bale chamber but of course also hay and straw with a very high bale density. The intake is developed to quickly fill the bale chamber like a fixed bale chamber. Ejecting the bale is also done at the speed of a fixed chamber baler due to a special bale chamber concept with two tension arms.
An HD baler-wrapper combination can achieve enormously high bale densities. High bale density ensures high feed quality and lower transport costs because there is more crop in a bale. The heavy-duty construction of the bale chamber makes the machine extremely robust. When a common bale density suffices, the service life is further extended because the machine is then oversized for the job.
In 2022, KUHN introduced the first variable high-density (HD) baler wrapper combination in the market: the VBP 7100 series.Advantages:
· Variable chamber so bale size can be varied
· Smart technology makes it easy to get a good bale shape
· Suitable for short and wet autumn crops
· The variable chamber is of course also very suitable for dry crops
· High capacity
· Very robustly built
· High bale density so high feed quality, lower transport costs, and when used for a standard bale density extra extended life of the machineTo take into account:
· Higher machine investment
· Larger tractor required compared to a fixed or standard variable bale chamber
Benefits of a baler wrapper combination
Harvesting quickly and cleanly, then preservation in airtight conditions is vital for a high forage quality. This is exactly what a baler wrapper combination does. The harvested crop is baled, bound and wrapped in quick succession so there is no time to lose dry matter content.
Other benefits are:
· Film binding: extra layers of film for better preservation, form stability and efficiency benefits
· Cost saving: only one machine a one tractor needed to do the job
· Time saving: no need to exit the tractor cab to change machines or tractors
High output boosts the profitability of your baling operation. That is why every building block is designed to ensure maximum capacity. Key elements are:
· Rotor and crop roller for crop intake
· Bale chamber and double tension arm for a guaranteed bale start, high densities and quick re-tensioning after bale release
· Quick tailgate and bale transfer
Net binding or film binding?
After the bale has left the bale chamber, it is important to maintain the bale density and shape. KUHN's binding techniques offer maximal holding force and optimal bale shape retention. In addition, film binding has many other advantages.
Net binding is the better option for dry crops such as hay and straw. The bale can breathe better because there is no film sealing around it. The KUHN Net binding system with active stretch technology ensures a firm bale shape with constant high net tension throughout the entire binding cycle.
The advantages of film binding
For silage conditions, film binding is the better option. When binding the bale with film the extra layers of film around the bale seal the crop in an airtight manner, thus ensuring better preservation and form stability. The development of mould in the bale is limited.
If you purely examine the costs for film and net, then binding bales with film is slightly more expensive compared with using net. But you can more than recoup those extra costs thanks to the many benefits of film binding:
· Faster and easier to open
· Less loss of silage
· Higher forage quality
· One type of waste
· Better yields
Switching between net and film
The KUHN film and net binding systems are two separate systems. Switching between the two is quick and easy - you do not have to change rolls and there are no tools needed.
KUHN film binding
You may take advantage of all the benefits of film binding while greatly lowering your film expenditures thanks to KUHN's patented TWIN reel film binding. The crucial point is the use of two regular 750 mm stretch-film rolls instead of special wide mantle film, which enables you to use a much higher pre-stretch ratio. This extends the film change intervals by 30% while lowering your film binding expenses by 37%. Additionally, the optional KUHN binding system uses the same film rolls as used for wrapping. This eliminates the need for special wide mantle film, which simplifies your inventory management.
After baling and binding, an optimal and intelligent wrapping process is the secret to getting the highest forage quality. 3D wrapping and INTELLIWRAP technologies offer the tools to maximise the preservation level and 'seal your profit'.
3D wrapping distributes the total film quantity more uniformly and efficiently across the entire surface of the bale. 3D wrapping will first apply the film where it is most needed: the vulnerable bale shoulders. The cylindrical wrap ensures that more air is excluded and that the bale retains its shape, even after long storage periods.
For good preservation, the number of layers of wrapping film is very important. It should be adapted to the humidity of the crop and the desired storage time. With standard wrapping systems, you can only wrap an even number of layers. But sometimes you need an odd number. With the unique
INTELLIWRAP technology you can determine exactly what your bale needs with one layer more or less (4, 5, 6, 7, 8, 9...). You don’t waste film and you use just enough to keep feed quality high during bale storage.
What type of crop can be baled?
In general, baler-wrapper combinations are able to handle a very broad range of crop types, from very wet to very dry and everything in between. Some examples: autumn grass, silage grass, clover, haylage, hay and straw. But each bale chamber concept (fixed or variable or variable high-density) has its own specialism or range. So choose the right concept so you can be assured of the best bale at the lowest cost.
Power requirement of the tractor
KUHN baler-wrapper combinations require a minimum PTO power of 80 kW / 109 hp. However, VBP 7100 series HD balers require a larger tractor compared to a fixed or a conventional variable baler: 110 kw / 150 hp. For more information, please consult the specifications on the relevant product pages: i-BIO+ / FBP 3135 / VBP 3100 series / VBP 7100 series.
Discover the KUHN offer:
· i-BIO+: Clever and Compact
The Unique Bale-In-One concept (integrated wrapper) is the basis of this ultra-compact, easy to maneuver and lightweight machine. Perfectly suited to hilly conditions and use on small or wet fields with narrow access gates.
· FBP 3135: High-quality bales at the lowest costs
Thanks to its robust design and unique options, this machine can boost your business' profitability.
· VBP 3100 series: Versatility and flexibility
Extreme versatility and flexibility all year round in terms of bale size and machine usage.
Variable high-density (HD) chamber:
· VBP 7100 series: The ultimate in power and versatility
The new league of combi balers; for the most demanding customer down to the last detail.
What are the technical specifications of KUHN baler wrapper combinations?
All building blocks of the machine are designed to offer the best possible productivity for your business, combined with optimal user-friendliness.
the balers feature several hydraulic systems such as rotor disengagement and integrated wrapper adjustment. Pivoting semi-pneumatic pick-up wheels are optional.
Where can I find a KUHN baler-wrapper dealer?
KUHN baler-wrapper combinations are for sale at authorised KUHN distributors.