Feasibility of Rebaling Large Round Bales of Hay

            At the 2006 Agriculture Trade Show Dr. James Leiby, University of Maine and Donna Lamb, University of Maine Cooperative Extension, Justin Jamison and Jake Dyer, University of Maine’s J. Frank Witter Center discussed this new “value added” hay marketing concept where large round bales are rebaled into small square bales. 

            This technique would allow farmers to harvest hay more quickly in the large round bales that could later be rebaled into more marketable small square bales for the equine and small livestock market.

            Horse hay needs to be dust and mold free to prevent respiratory distress in horses.  In Maine’s weather it is a challenge to get the hay cut, dried, raked and baled and into the barn before wet weather.  One method to help reduce the time from cutting and baling is to spray the hay with a buffered acid preservative just as it goes into the baler.  Acid treated hay can be baled at a higher moister level without danger of mold.  Acid treated hays have been fed to horses with no negative effects, and after a brief adjustment period, the horses find the hay quite palatable. 

            It is estimated that there are about 38,000 horses in the state of Maine.  Each needs about ˝ bale hay when not on pasture.  This would be equivalent to about 7 millions bales of hay per year with a value of about $22.5 million.

            An Iowa State study found that baling hay into the small square bales costs $14 per acre more than round bales.  This doesn’t include the extra handling costs associated with small square bales. 

            A University of Georgia study found that the average price beef producers were willing to pay for hay in large round bales was $50 to $60 per ton which is very near the cost of production.  But when the same hay was put up into small square bales and marketed to horse owners the price went up to $150 per ton. 

            The Franklin J. Witter Center at the University of Maine has been using a Simpco Inc. hay rebaler for a number of months.  The designer T. Whipple Simpson was trying to market small square bales and found he needed a crew of six to bale and stack ten acres of hay or straw a day.  With round bales, four people could very easily cover 15 acres a day.  He built the hay rebaler to unroll and fluff up the hay from a large round bale and then he used his regular square baler to rebale the hay.  He found that his 800 pound round bale valued at $37.50 would yield 19 small square bales weighing 40 pounds valued at $3.25 per bale. This is a $16 gain per round bale without including the extra costs of the square baling operation. 

            The preliminary experience at the Witter Center has shown that 3.5 workers (operator, stacker, loader – floater and cleanup person) can rebale about 6,000 pounds an hour.  They need two tractors (one for power and one to load) and their square baler. The rebaling operation produces a lot of dust and chaff so it is suggested to locate the operation in an area that has good ventilation.  

            The total cost per hour to rebale 7.5 large round bales was $357.16.  This includes the cost of the bale.  The 145 square bales valued at $3.25 each or $471.25 results in an increase net revenue of $114.09 per hour, or $15.21 per round bale or $0.79 per square bale. In the worst case scenario with round bales costing $45 and wages at $13 per hour the break even price for square bales would be about $3 per bale. The rebaling costs alone were $75.91/hour, $10.12 per round bale or $0.52 per square bale.

An important point is that rebaling hay can not improve the quality of the hay.  You need to start with dry hay that has been stored under cover.  Hay that has a large amount of spoilage on the outside or bottom of the bale usually binds up the equipment. So those looking for an option for rebaling spoiled hay into small square bales for mulch hay should not rely on this equipment. 

            The Simpco Inc. contact information is T. Whipple Simpson, Route 2, 247F, Cochran, Georgia 31014, phone (478) 934-7863. email simpsonfarms@yahoo.com. The preceding does not constitute a recommendation for this equipment and is provided for information only. To see this equipment in use contact either Farm Superintendent Justin Jamison (207)581-2793 or Forage Manager Jake Dyer (207) 745-6181.

            Another value added hay market being investigated is the “Mini-bale” or half a regular square bale that weighs about 20 pounds compared to 45 pound regular bale. The smaller size bale would be easier for small statured horse owners to handle. 

            If you would like to contact any of the folks involved with this project here is the contact information.  If you have any ideas or experience with the equipment that you are willing to share please feel free to contact any of these folks.

Dr. James Leiby, University of Maine, Resource Economics and Policy, (207) 581-3178, James.Leiby@umit.maine.edu

Donna Lamb, University of Maine Cooperative Extension, (207) 564-3301 or in Maine (800)287-1491, dlamb@umext.maine.edu

Justin Jamison, Farm Superintendent, University of Maine, Witter Center, (207)581-2793, Justin.Jamison@umit.maine.edu. 

Jake Dyer, Forage Manager, University of Maine, Witter Center (207) 745-6181, Jake.Dyer@umit.maine.edu .