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David H. Staheli. President.

Staheli West. Inc.,

1280 West 3695 North, Cedar City. Utah 84720;

Published In: Proceedings, 27th California Alfalfa Symposium. 10-11 December, 1997. Visalia. CA,

UC Cooperative Extension, University of California, Davis.

Edited Nov. 2009 to reflect changes in operating costs, new developments, etc.

STEAM DEW SIMULATION

HAY BALING OPERATIONS

PURPOSE

PROCESS

CONTROL

David H. Staheli

ABSTRACT

To overcome problems relating to the maintenance of proper moisture conditions of hay during hay baling operations, the Dew Simulation Process has been developed and patented.

This is a controllable process which allows the creation of good baling conditions at any time of the day or night as long as the hay to be baled is sufficiently dry at the time of baling. The only exception to this is that in some cases where very high afternoon temperatures prevail, baling in the cooler parts of the the day and at night is preferred.

Dew Simulation is accomplished by the use of a tractor, a mobile steam generating system and a hay baler equipped with a steam injection system. These three major components are attached together in series and work as a single unit with one operator. As the operator commences the baling operation, a controlled volume of steam produced by the steam generating system is injected into the hay as it is lifted from the windrow and passes through the feed system of the baler. The steam utilized to treat the hay passes through a series of nozzle equipped manifolds which are located at various positions above and below the pick-up mechanism and feed chamber of the baler. As the hay is baled the operator is able to monitor bale moisture and make necessary steam flow adjustments from the tractor seat on the fly to maintain consistent favorable baling conditions even in varying ambient conditions which occur during different times of the day or night.

THE PROBLEM

In Hay Production Operations the producer is faced with many obstacles as he attempts to grow, cut, cure, bale, haul, store, market and transport high quality feed. Weather, atmospheric conditions and machinery requirements are a few of the major challenges.

Baling High Quality Hay is especially challenging, with one of the most difficult conditions being the proper moisture requirement for the baling process. Until now, the producer has had to rely almost totally upon the natural dew process to get proper moisture conditions to preserve the quality of hay during baling operations, especially in Alfalfa and similar leafy legume type forages.

In the more arid western states of the U.S.

and other dry areas of the world this

becomes a devastating problem at times

when atmospheric conditions just will

not allow dew formation. Baling such

forages dry causes substantial loss

and/or damage of the most valuable

leafy portion of the forage, the shattering

of the stemmed portion, loss of protein

and other feed values, difficulty in loading,

hauling and feeding and losses in market

value.

At other times the problem makes a radical swing in the other direction with good dew conditions for baling coming on early in the evening, only to become to wet within an hour or so, forcing the operator to stop and wait to bale until the next day or to face expensive crop spoilage.

A Hay Producer cannot consistently count on natural dew to provide what would be considered as "Good" baling moisture. Even the window of "Tolerable" natural baling moisture is usually quite small during any 24 hour period. Consequently, producers who wish to put up reasonably good quality hay crops are forced purchase enough tractors and hay balers to complete baling processes within the small window of time when tolerable moisture conditions are more likely to prevail.

THE SOLUTION

Steam Dew Simulation in hay production is a process of adding moisture in the form of steam vapor to dry crop material during the baling process. In baling operations, where a small, controlled amount of moisture is desirable in the tissues of dried forages, Dew Simulation empowers producers to effectively maintain good quality baling moisture conditions consistently in forage feeds such as alfalfa and grass type forages.

The Dew Simulation process uses Steam as the reactive moisture source because:

The properties of steam enable it to be absorbed instantly by dry plant tissue.

Steam has a volume of approximately 1700 times more volume by weight than water as a liquid. This allows thorough controlled steam treatment of the hay as it is baled, without over wetting the hay.

Utilizing the high volume of the injected steam in a well-designed injector arrangement every surface of the plant tissue comes in contact with steam vapor.

Because of the temperature differential between the injected steam and the dry plant tissue, as the steam makes this contact, it immediately condenses on the cooler surface of the plant tissue causing instant absorption.

This Dew Simulation process provides baling moisture of a very high quality and allows for adding more or less moisture as ambient conditions demand, on a predictable, controllable and consistent basis.

_________________________________________

Though quite simplistic in principle the "Steam" Dew Simulation process is extremely effective in changing dry, brittle hay to an ideal soft, slightly moist state for baling. This effect is created instantly during the baling process.

Research and field testing has proven that while steam absorbs very rapidly into dry hay tissue, it also evaporates off from these same plant tissues very quickly. This is especially true in dry, windy conditions. Under most conditions it is not possible to effectively steam treat hay for baling while it lies in the windrow any distance ahead of a hay baler. Sufficient moisture will not remain in the hay long enough to pick it up from the windrow, move it through the feed chamber and into the bale chamber.

Thus through the Dew Simulation Process as defined here, steam is delivered to the dry hay through a series of injection manifolds mounted at various points above and below the baler pickup mechanism and baler feed chamber. As the hay is lifted from the windrow and is moved through the feed chamber of the baler, a continuous, controlled amount of steam is injected to bring the hay to a predetermined moisture level. The softened hay is then moved into the bale chamber or flake forming chamber (as in large square balers) where it is compressed at which point added moisture is retained in the hay.

The moisture level in the bale is then monitored as the bale is pushed through the bale chamber to enable the operator to make adjustments to the steam application rate as needed to maintain a consistent moisture level in his bales from start to finish. Remote monitoring and control functions of the machinery are accessible to the operator on the go through metering and control components mounted near the drivers seat.

The convenience and effectiveness of the Dew Simulation Process is truly amazing. It adds a level of control and flexibility to Hay Baling Operations that has never been possible before. We believe this new technology will revolutionize commercial hay production in the western United States and in other arid areas of the world.

ADVANTAGES of STEAM DEW SIMULATION

Dew Simulation overcomes many of the problems of commercial hay production in several ways.

Using Dew Simulation a producer can bale hay at any time after the hay is dry with no need to wait for natural dew to form. The only exception to this is that in some cases where very high afternoon temperatures prevail, baling in the cooler parts of the the day and at night is preferred.

Addition of moisture through this process can be regulated according to the need. meaning that a baler can usually be operated for 24 hours a day if necessary, except in cases where natural dew becomes too heavy.

The Dew Simulation process is the first method developed that will allow the monitoring and maintenance of consistent moisture percentages in the finished product from the first bale to the last one during an extended time frame.

Dew Simulation makes automated bale handling and hauling operations cleaner and easier, and minimizes hay dust during baling, handling, transport and feeding operations. Each flake of the bale is more defined and compact, minimizing leaf loss and waste during handling and feeding.

This improved bale quality is possible because when using steam to moisturize the hay as it is baled, you can create very soft, pliable hay while baling, without raising the actual moisture level in the bale above 12-15%. This effect is consistently replicated as long as the hay is well cured and natural dew is not too heavy at baling time.

Dew Simulation provides significant benefits with regards to storage and truck and ship transport of hay. As mentioned above, using this process to provide your baling moisture, you can bale with thorough high quality steam injected moisture which provides excellent baling conditions, yet the moisture reading of the bales will be at an acceptable level for storage and shipping.

Also, when using steam, Bale Density can be increased by 20 to 25% if desired, while baling at equally higher Field Baling Speeds and utilizing the same tractor horsepower. This is why:

When the hay is treated with steam it is warm and soft. It is simply easier for the baler to pack into the bale. When you Iron your shirt at home, the steam from the iron combined with the pressure from the iron flattens the wrinkles. The effect is the same on steam treated hay as it is compressed by the baler plunger.

SO, at equal plunger load settings in Large Square Balers, each flake of steam treated hay will contain more hay (because of higher density) at the same thickness than hay baled with only natural dew. This will produce a heavier bale.

How is Field Baling Speed Increased?

Most Large Square Baler Operators like to feed their baler fast enough that the Stuffer cycles to feed a flake into the bale chamber on almost every Plunger stroke. It is a matter of baler efficiency.

Most Large Square Baler Operators also like to put 35-40 flakes in each bale. So lets use 35 flakes (since steam treated hay makes very nice bales at 30-35 flakes per bale).

With only natural dew, If I am baling at 9 MPH making a 1250 lb. bale with 35 flakes and my Stuffer is cycling on every Plunger stroke, I am putting 36 lbs. of hay in each flake.

When baling with steam, I can expect to increase my bale weight to around 1500 lbs. at equal Plunger load pressures. This would put 43 lbs. of hay in each flake and if I maintain a flake count of 35 flakes per bale with my Stuffer cycling on every Plunger stroke I can increase my field speed to 11 MPH, about 20% faster.

20 - 25% increases in Bale Density and Field Baling Speed are typical when using Steam Dew Simulation.

Increased bale density allows more tons of hay to be stored under valuable barn space and fewer bales are needed on trucks to reach legal weight limits.

Dew Simulation can cut a producer's tractor and baler requirements by 50 - 75%, because the window of time when baling can be done is expanded in some cases to nearly 24 hours in any given day, instead of only a few hours when natural dew is present.

Fewer machines running in the field also means lower labor costs. Finding good competent operators is more affordable when they spend more time operating machines instead of filling their time with "make work" while they are waiting for a few hours of baling time each day.

The cost of the Dew Simulation machinery and the cost to operate it is more than offset in reduced overall machinery and labor requirements.

Most hay farmers in the West have endured periods of harvest time when there simply is no natural dew for several days or longer. The loss in the value of a good crop of hay can be tough on the bottom line. With this Dew Simulation Process a farmer who bales hay will never again have to bale without dew and sell over dried hay short of it’s potential value.

Any Farmer who is skilled in farm finance knows that the extra few dollars per ton of hay, the additional ton per acre, or the little bit of added efficiency makes a big difference in his bottom line.

COST OF OPERATION

We have calculated the cost of operation of the Dew Simulation Process on a "Cost per Ton of Hay Processed" basis with average steam application conditions. The actual cost of operation will vary depending on what times of day the operator chooses to bale.

Under hot, dry, adverse conditions you might add as much as 60 lbs. of steam (about 7 gal. of water) per ton of hay to achieve "Ideal" moisture levels for baling. This will require #2 diesel fuel consumption of about 3/4 gallon per ton of hay baled, to convert the required water to steam.

During cooler times of the day or in the night time you might only need to add 20 lbs. of steam (about 2-1/2 gallons of water) to reach optimum moisture levels for baling. This will require #2 diesel fuel consumption of only about 1/4 gallon per ton of hay baled, to convert the required water to steam.

We will use an average of 40 lbs. of steam (5 gal. of water) per Ton of Hay Baled as a basis for the cost of operation.

Cost of Operation per Ton of Hay Baled: (November 2009)

Fuel @ $2.30/gal.

Average ½ gallon fuel consumption per Ton of Hay Baled = $1.15 per Ton of Hay Baled.

Average Cost/Ton. to treat water for Dew Simulation Machine boiler. = $0.10 per Ton of Hay Baled

TOTAL Operating Cost per Ton of Hay Baled = $1.25

COST OF SUPPORT EQUIPMENT

The Cost of Support Equipment is somewhat dependant upon the logistics of your Farming Operation. Some factors are:

The distance from your fields to adequate water supplies to meet the Dew Simulation Machine requirements.

The machine carries 1000 gallons of water per load which will be enough to bale an average of 200 Tons of Hay. (Of course this will vary depending on ambient baling conditions). This means you will be able to bale hay for an average of 4-6 hours per load of water with a Large Square Baler and a Dew Simulation Machine.

The availability of Water Storage Tanks, Transfer Pumps and perhaps a Water Truck or Trailer if there is a need to transport water to the field.

To determine the Cost of Support Equipment for your Farm Operation, you need:

1.To decide whether or not you will need to transport water to your fields to supply the Dew Simulation Machine during baling operations. Of course you will greatly increase your operating efficiency by providing a supply of water close to the fields where you will be working. In cases where you are trying to push through a lot of acres in a day a Water Truck or Nurse Tank Trailer at the fieldside will prove worthwhile.

2.To determine whether you need water storage tank(s) to accumulate and store water from culinary or other water systems. Each Dew Simulation Machine will consume 1000 gallons of water every 4-6 hours under normal operation. Some sort of water storage tank (even one on a truck or trailer) at the water source can be used to collect water while the machine is out operating in the field. The use of a float valve in the storage tank will allow you to let the water run into the tank unattended and will insure a full tank when you return

3.The DewPoint 6110 is loaded with water through a single 2" camlock connection at the rear right side of the machine. You will want a pump that is capable filling the 1000 gallon capacity of the machine in 5 minutes or so. A 2 inch Transfer Pump, a water treatment Chemical Induction Tee and 2 inch suction and discharge hoses with camlock fittings are used to pump treated water from the storage tanks or Water Truck or Trailer into the Dew Simulation Machine supply water tanks .

The cost of these components will vary depending upon your own resources and the nature of your farm operation. Many growers will already have most or all of these support components.

COST COMPARISON OF EQUIPMENT

The bottom line is that you can replace the productivity of 3 to 4 conventional Large Square Balers with 1 Large Square Baler equipped with the DewPoint 6110 Dew Simulation Machine.

It is common for many commercial hay farming operations to have at least 1 Large Square conventional Baler for every 500 acres of hay they produce and they often still struggle to get acceptable natural dew conditions for baling.

1 Large Square Baler equipped with the DewPoint 6110 Dew Simulation Machine can adequately handle up to 2000 acres on a 5-10 day baling cycle.

It is easy to bale an average of 250 acres per day with this one machine in a 10-12 hour day. Of course, you can put in longer days if necessary and bale up to 500 acres or more in a 24 hour period.

Baling using Dew Simulation gives you the ability to:

Keep a consistent cutting schedule between crops to maximize feed values

Quickly, bale and remove the crop being harvested, on a regular schedule, to allow irrigation and regrowth of the next hay crop as soon as possible

Bale large quantities of high quality hay ahead of afternoon or evening thunder showers when necessary

Bale high quality hay when natural dew formation is insufficient

Raise feed values in hay crops above what can be achieved even with common natural dew conditions

These are just a few factors that can

make a substantial difference in the

bottom line for a hay producer. As

you know, the lack of the right

equipment in the hay business

can be far more expensive than

the cost of the right equipment.

Hay which is devalued by just because there was no natural dew for a few days or a week (a common scenario) takes a heavy toll. Dew Simulation gives the producer a greater ability to protect and preserve the value of the hay crop he has on the ground after he has done everything else right to get it to that point.

SUMMARY

Dew Simulation as discussed here has been under development since 1994 and was field operable with a prototype in 1995 with a 3-string baler. In 1996, two, more advanced prototypes were successfully tested on a 3-string and a 1- Ton square baler respectively. In 1997 nine more upgraded units were built and placed in Idaho, Utah and Nevada. Since then units have run in Texas and California.

From 1998 to 2007 a great deal of work was done to evaluate, analyze, develope and improve the efficiency and opreation of the Dew Simulation Process. Several different machine configurations were tested in various venues in Utah and in Arizona.

In 2008 -2009 the latest market intent DewPoint 6110 was designed, built and field tested with new user friendly computer control systems. It is very easy to use. A communication modem is part of this new series which allows Remote Internet Access to the machine when technical help or training of new operators is required.

This process has proven effective as a revolutionary new concept in commercial hay production. On Brent Hunter Farms in Cedar City, Utah we are running one MF Hesston 2170 3x4 Large Square Baler coupled with a DewPoint 6110 Dew Simulation Machine. Our farm acreage is 1800 acres of hay. We get 4 cuttings of alfalfa each year. We are able to easily cover all 1800 acres of baling with this one machine.

We often ask ourselves, "How does anyone do this the old way?"

Whether we are baling 1st or 2nd crop Alfalfa in June where there is little or no natural dew in the day or night, or fighting the excessive night-time dews of July and August, the DewPoint 6110 coupled with our 3x4 baler puts us in the drivers seat making good hay without any hassle.

We never want to go back to sleeping in the front seat of a pickup night after night, in hay fields waiting for the dew to come in.

We don't really care what time of day or night we bale hay, we just want to "go" when we get there.

________________________________________

Questions regarding Dew Simulation

may be addressed to:

Dave Staheli.

Phone 435-590-2537

Or e-mail: dave@staheliwest.com

Staheli West, Inc.

642 North 1070 West

Cedar City, Utah 84720.

The following information is edited from a "Proceedings" paper Published In: Proceedings, 27th California Alfalfa Symposium. 10-11 December, 1997.

Visalia. CA, UC Cooperative Extension, University of California, Davis.

Edited Nov. 2009 to reflect changes in operating costs and new developments and to bring other outdated information up to date.

This is a treatment of the subject of Steam Dew Simulation in Commercial Hay Production but does not contain all the details that are currently available.

We hope you learn some interesting things from what you read here, but please feel free to contact me with any questions.

Thanks,

Dave Staheli

SO WHY NOT JUST SPRAY WATER INTO WINDROWS OF HAY TO SIMULATE DEW?

Actually this method can work if the conditions are just right. But like "natural dew", often the conditions are not right or are limited to a small window of time each day.

Attempts by farmers to put moisture onto or into their dry windrows of hay, by spraying it with water with field sprayers or with high pressure injection systems prior to baling have had some success under favorable conditions, however there are limitations and downsides to these methods.

Chemicals are often added to water to speed absorbtion. These cost money too and who wants chemical surfactants in their hay?

Since the absorption rate of the moisture into the plant tissue is relatively slow, even with the chemical additives, this method does not work well in breezy or daytime conditions. The water evaporates before it penetrates.

More equipment and operators are required to apply the water treatment in a seperate operation ahead of each Hay Baler.

There is a required time lapse between water application and the baling operation, to allow the applied water to absorb into the windrow. This necessitates some trial and error to try to balance the timing of the water application with the baling operation where crop conditions and ambient conditions are always changing. 15-30 minutes after the water has been applied by the Sprayer Operator, the Baler Operator lets him know if he put on enough water. It is a clumsy control method at best.

Water Consumption Rates are much higher when spraying water into dried hay windrows than when using steam. Again, because of the required time lapse between spraying and baling most of the applied water evaporates into the air while a smaller percentage actually absorbs into the hay.

In small hay farm operations a water injection system which sprays water into dry windrows of hay can fit quite well, but for Commercial Hay Operations it is cumbersome and inadequate for "Production Baling Operations".