In this article, you will learn what a forage harvester is, the different types available, and what to consider when choosing one. We also cover suitable ensiling methods.
What Is a Forage Harvester?
A forage harvester is an agricultural machine that cuts green forage crops in the field, chops them to a suitable length, and prepares them for ensiling. It is used to harvest crops such as maize, sorghum, alfalfa, meadow grass, and whole-crop cereals.
After chopping, the crop is fermented in an airtight environment. This helps meet winter forage needs and ensures a lasting feed supply. Compared with traditional haymaking, silage offers an alternative that can preserve nutritional value for longer and minimize storage costs.
Because crops intended for silage are processed immediately after cutting, harvest losses, labour requirements, and energy costs are minimized.
What Are the Different Types of Forage Harvesters?
A forage harvester is an agricultural machine that harvests green crops in the field, such as maize, sorghum, alfalfa, or meadow grass, and chops them to a specific length for use as animal feed. When classifying forage harvesters, the first consideration is their role in the silage production process:
1 – Harvesting / Chopping Machines are classified according to two criteria:
A. By Row Configuration: Single-Row and Row-Independent
B. By Target Crop and Chopping Method: Maize Harvesters and Double-Chop Grass Harvesters
2 – Compaction and Spreading / Distribution Machines are classified by working width rather than the number of rows (e.g., 2.5 m / 3 m).
3 – By Mounting and Mobility: This classification is independent of the two categories above, as it applies to harvesting, compaction, and spreading / distribution machines:
A. Mounted
B. Mounted with Support Wheels
C. Trailed
D. Self-Propelled
Which Machines Are Used in Silage Production?
Producing high-quality silage requires a series of complementary operations, rather than a single machine. This process can be divided into three main stages:
Harvesting and Chopping: The crop is cut in the field, chopped to the desired length, and transferred into trailers. The Çelikel Challenger and Calabria series are used at this stage.
Compaction: The chopped material is compacted in a silage pit or pile to remove air pockets and create the conditions needed for fermentation. The Çelikel Blackout series is used at this stage.
Spreading and Distribution: The material is spread evenly in thin layers, particularly in large silage piles. The Çelikel Blowout series was developed through research and development to meet this need.
What Are the Different Types of Forage Harvesters?
Harvesting and chopping machines come in different models depending on the crop to be processed and the size of the farming operation. These include:
Single-Row Forage Harvesters
Designed for small and medium-sized farms, these models require low tractor power and make harvesting tall maize easier. Their row-following system helps save both time and energy, particularly when harvesting tall maize.
Row-Independent Forage Harvesters
With their wide cutting drum unit, these machines harvest maize and forage crops over 1 metre tall regardless of row direction. Since the machine does not need to align with the planted rows, fewer turns are needed in the field, and less crop is run over by the tractor.
Models with 2-, 3-, or 4-row harvesting capacities can be selected according to farm size and the area to be harvested. The Çelikel Challenger 2, 3, and 4 series fall into this category.
In addition to maize, these models can also harvest suitable grass crops. However, if wilted grass requires an extra-fine chop, double-chop models should be preferred.
Double-Chop Grass Forage Harvesters
These machines are designed for extra-fine chopping of wilted grass and forage crops. Their patented rotor system picks up the crop from the ground and performs an initial chop before feeding it to the flywheel for a more precise chop length. The Çelikel Calabria series falls into this category.
Silage Compaction Machines
Compaction removes air from the silage pile, allowing proper fermentation. If air remains trapped, the silage can develop mould, heat up, and lose nutritional value.
Silage Spreaders
These machines spread material quickly and evenly in thin layers across large silage piles, eliminating waiting time during filling and providing a cost-effective solution for farmers.
What Should You Consider When Choosing a Machine?
Çelikel Agricultural Machinery draws on a wide range of sources to develop machines that meet the needs of farmers and agricultural businesses. Field studies, case analyses, user experiences, technological advances, and varying capacity and crop requirements form the foundation of this process.
Our goal is to lead the shift from traditional farming methods to more efficient, cost-effective, and technology-based solutions. By helping farmers choose the right machine, we aim to save them both time and resources..
Working Width and Number of Rows: | Your choice should depend on the size of your farm and the area you aim to harvest each day or season. Working width refers to the width of crop a machine can harvest in a single pass. Single-row models may be sufficient for small farms, while farms with larger areas may benefit from row-independent models with 2-, 3-, or 4-row capacities, helping save time and labour. |
Chop Length: | Chop length refers to the size of the pieces into which the harvested crop is cut and directly affects silage quality. Crops chopped to the correct length are easier to compact and ferment more effectively. |
Kernel Processor (Grain Cracker): | This component is specifically used for maize silage and crushes the kernels. If the kernels remain intact, animals cannot digest them effectively and therefore cannot fully benefit from their nutritional value. It comes as standard on some models and is optional on others, so checking whether a maize forage harvester includes a kernel processor is an important selection criterion. |
Tractor Power Compatibility: | A tractor with insufficient power can cause blockages and reduce throughput (the amount of crop processed). Using a tractor that matches the machine’s required power take-off (PTO) speed (540 / 540E / 1000 rpm) improves efficiency and ensures reliable operation. |
Crop Type: | Maize silage and grass silage have different requirements: kernel processing is a key consideration for maize, while double chopping is important for wilted grass. Choose a model suited to the crop you will be processing.
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Knife Sharpening System: | Keeping the knives sharp helps maintain a consistent chop length. As the knives become blunt, chop length increases, requiring more power and making the silage harder to compact. Regular sharpening and an automatic knife sharpening system help prevent these problems and keep the machine operating efficiently. |
Compaction and Distribution Requirements: | As harvesting capacity increases, so does the need for compaction machines and silage spreaders. Beyond a certain capacity, a decline in silage quality can result in wasted investment and labour for farmers and agricultural businesses. |
Forage Harvester Price Ranges
These price ranges apply to standard configurations. Prices may vary depending on the optional equipment selected. To find the machine and model best suited to your needs, we recommend requesting a quote from Çelikel Customer Service and our expert sales team.
Frequently Asked Questions
1 - How Many Rows Should a Forage Harvester Handle?
This depends on the size of your farm and the area you plan to harvest. Single-row models may be sufficient for small and medium-sized farms, while farms working larger areas can save time and labour with row-independent models offering 2-, 3-, or 4-row capacities (Challenger 2, 3, and 4).
2 - Can the Same Machine Be Used for Maize Silage and Grass Silage?
Row-independent models can harvest suitable grass crops as well as maize. However, if wilted grass requires an extra-fine chop, double-chop models (Calabria) should be preferred. Since kernel processing is important for maize and double chopping for wilted grass, we recommend choosing a model based on the crop you will be processing.
3 - Are Compaction Machines and Silage Spreaders Really Necessary?
Yes, these two stages are just as important as harvesting for silage quality. Compaction removes air from the pile to support proper fermentation, while spreading and distribution ensure the material is evenly spread in thin layers across large piles, reducing the risk of spoilage.
4 - What Is the Minimum Tractor Horsepower Required for a Forage Harvester?
The required power varies depending on the machine model and PTO speed (540 / 540E / 1000 rpm). A tractor with insufficient power can cause blockages and reduce throughput. We recommend checking our catalogue for each model’s minimum power requirements and contacting our customer service team for more detailed information.
As arable land becomes increasingly limited and the global population continues to grow, we aim to help increase food production by leading the way in agricultural mechanisation and automation. Our goal is to help meet people’s basic nutritional needs. Contact us for advice on choosing the machine best suited to your needs.
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