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?