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Agricultural Engineering Today, Vol. 25 (5-6) : 1-14, 2001

AVAILABILITY OF WHEAT STRAW IN COMBINE HARVESTEDFIELDS FOR BALING

T.C.Thakur! and Pramod Rajan2

ABSTRACTIncreased mechanization has made the straw recovery and itsutilization difficult for the farmers, The use of grain combine harvesterin rice-wheat regions of India is increasing at a faster pace. Off-fieldutilization of paddy and wheat straws continues to get attention dueto concerns regarding environmental impacts from open field burningofthe crop residuesfor its disposal. Thefield baler is recent introductionin India for recovery of combine- harvested straw for its utilizationeither as animal feed or by paper and board making industries. Theknowledge of straw availability and losses are of paramountimportance for determination of economics of the system. The studyconducted on three wheat varieties has revealed that at the prevailingheight of cut of 35-90 em by combine, the straw availability was in therange of 1400-2000 kgDM/ha out of potential straw availability of4900-6400 kg DM/ha. Also the average linear density of swath wasfound to be about 0,98 kgDM/m as against reguired density of 1.72kgDM/m for full loading of baler, thereby, suggesting the introductionoffield rakes for windrowing or lowering the height of cut of combine.

I. INTRODUCTION

The increased mechanization of harvesting of cereal crops has drawn theattention towards collection or removal of crop residues from the field, The cerealcrops production crossed the 200 million tonnes mark in 1998-1999 in whichwheat and rice both account for about 165 million tonnes. On an average, forevery four tonnes of wheat or paddy, nearly six tonnes of straws are producedwhich shows a huge amount of crop residue available for disposal every year. Inthe northern states of Uttar Pradesh, Uttaranchal, Punjab and Haryana, the traditionalharvesting using sickle has been largely replaced by combine harvesting speciallyin the case of wheat and paddy.

I. Professor & Joint Director Research (Engg.), G.B.Pant University of Agri. & Tech.,Pantnagar - 263145 (Uttaranchal)

2. Ex-P.G.Scholar, Department ofFarm Machinery & Power Engg., College ofTechnology,Pantnagar-263 145 (Uttaranchal)

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In the process of combining about 40-60 % of recoverable straw is lostbecause of high cut of the crop, which in tum increases the efficiency of combine.A higher level of cutting improves the quality, but reduces the availability of straw.The method of harvesting influences both, the quality and quantity of straw. Earlyharvest may provide good quality straw but the grain quality and production arenegatively affected (Alam, 1998). Harvesting of the plant is done at a certainheight for two reasons: (i) The bottom part is generally waterlogged (rice), coarseand is not easily relished by cattle and (ii) It is incorporated into the soil to maintainsoil health.

Since the collection of left out biomass is labour intensive operation, farmersnormally bum the straw, which is an economical mode of disposal, but this practiceis unacceptable as it is against good environmental practices. Cereal straw couldbe collected and baled from behind the combine harvester with the help of a fieldbaler. Several methods of collection, packaging and handling of straw have beentried in the developed countries. Baling of straw, either in rectangular or big rollbales provides the most adaptable system available for collection and removal ofstraw from fields following combining (Dobie et al. 1977). In India, baling can beused as an option to collect the huge amount of residue left after combining inorder to decrease the adverse effects of open field burning on environment. Further,the total value concept of crops would be the focus of future in which the mainproduct as well as the byproduct will have to be utilized.

There are many factors affecting the amount and quality of straw producedper unit area such as variety of the crop, agronomic practices, and environment,harvesting, threshing, cleaning and handling practices. The potential straw yieldis obtained by subtracting the rain yield from above the ground yield of the crop.Grain yield can be measured accurately, however, straw yields are reported withless accuracy because of variations in height of cut under field conditions and lossof chaff and leaves when sampling is done following a combine harvester. Thestraw yield is usually calculated from grain production data based on straw: grainratios. This ratio is the best available means of estimating straw yield in the absenceof sufficient measured data (Kossila, 1984 and Siebeamorgan et aI., 1994).Generally the straw: grain ratio of wheat varies from 1.2: 1 to 2.6: 1 and averagedat 1.5:1 (Alam, 1998).

The mode of harvesting of the crop either by machine or manual can affectthe cutting height and therefore, the amount of recovery and quality of straw.Straw quantity is closely proportional to the height of cut (Smith et aI., 1975 andAllen, 1998). The cutter bar of the combine is operated at the best height foroptimum combine efficiency, as more and more straw is fed into the combine per

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unit time, the poorer becomes the grain detachmeilt and separation, resulting inhigh grain losses. Farmers give priority to grain harvest and leave long stubbles tomaximize combine throughput and to reduce the cost of harvesting. The handlingefficiency of straw is affected by swath characteristics (FIilmersen et aI, 1984 andNeale and Williams, 1993). The type and size of crop, grain straw ratio and cllttingheight are the factors that determine the density of swath. It is important to makeswaths with uniform size and density by using a rake if the straw is to be baledefficiently. Thus keeping the above point in view, it was felt necessary to conducta field study on swath characteristics, potential straw yield, straw available forrecovery after combining, baler losses and straw recovered by a conventionalfield baler so as to project the availability of straw under prevailing harvestingcondition by a combine harvester.

2. MATERIALS AND METAODS

Investigations were carried out on three varieties of wheat namely, UP2341, UP2338and UP2687 in the year 2001 for all the varieties sample areas of 1 m2 weremanually harvested at ground level using a sickle when the crop reached at itsharvest maturity. These samples were used to determine the potential straw yield,straw: grain ratio, straw availability and losses as stubbles. The methods used fordetermination of these parameters are described below:

2.1 Potential straw yield

This experiment served as a control treatment. Whole plant samples wereharvested from randomly selected sample areas at ground level. The plants werecarefully fastened in bundles keeping the lower ends of the plants at par. Theheads were separated from stalks and thereafter, weighed and threshed. The weightsof grains 'and stalks were measured and representative samples were taken fordetermination of moisture content. Later on 5 to 6 segments having a length of100 mm each were cut one after another from the stalks starting from the root side.The weights of each segment and also the weights of the remaining portion ofstalks at the' panicle side Were measured. The results of weight measurementswere worked out in terms of dry matter weight per hectare. On the basis of thesemeasurements the straw availability at a given height of cut was calculated asfollows:

Y, ,=Y -Ls1 p

Where,

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Yh =Yp =Ls =

straw availability at 'h' height of cut, kgDMlhapotential straw yield, kgDM/ha andstraw losses as stubble, kgDMlha.

2.2 Actual straw yield

The actual straw yield was determined indirectly using linear density ofswath which is defined as the weight of loose straw found in one-meter length ofswath. The results of this experiment were used to estimate straw availability inswaths and straw losses associated with the combine: A. commercial combine (HIRA985) which had a cutter bar width of 4.5 m was used for combining the crops.Loose straw present in each meter of selected swath segments was collected usinga manual fork and weighed. Representative straw samples were taken fordetermination of moisture content. Straw losses due to combining represent theamount of chaff and straw that has been shattered and perished on the ground dueto mechanical action of different units of combine and that cannot be collected.These losses were estimated as the difference between the straw potentially availableat a given height of cut and effective straw availability in swaths as given below:

Lc =

Where,

Lc =Yh =Ph =Wc =

Yh

-10,000 (p/wc)

straw losses due to combining, kgDM/hastraw availability at 'h' height of cut, kgDMlhalinear density of swath at 'h' height of cut kgDM/ha andeffective width of cut of combine, m.

2.3 Baling losses

Straw losses by the baler include the losses incurred at the pickup unit and balechamber of the machine. Pickup unit loss is the loose straw that is left over theground surface as the swath is lifted by the pickup unit and is affected by swathparameters and straw moisture content. Bale chamber loss is the material that isdisassociated and dropped during the formation of bales in the bale chamber.Baling was carried out at three different speeds in swaths having a length of 120 meach and the total width of the field upto about 26 m using a conventional CLASSMarkant- 55 model baler which produces bales of 36 x 46 cm cross sectionaldimensions and lengths varying from 40 to 110 cm. The field baler was operatedby a 37.5 kW tractor. The number of bales produced in each plot and the weight

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of bales were taken. Representative straw samples were collected for determinationof moisture content. The baling loss has been considered as the difference betweenthe effective straw availability in a plot and the yield of baled straw and wascalculated using the following formula:

total weight of bales collected from a swath, kgDM and

length of swath, m.

Lb =

=

Where, Lb =

Wb =

Bs =

(1 O,OOO/w)(Ph- W/B.)

baling losses, KgDMlha

... (3)

3. RESULTS AND DISCUSSION

3.1 Effect of height of cut on straw availability

The results of crop sampling in relation to grain yield, potential straw yield and

straw availability at different heights of cut are presented in Table 1 for three

wheat varieties. All the varieties were medium tall varieties having the mean height

of plants excluding the earheads as 74 cm for UP 2338, 78 cm for UP 2382 and 79

cm for UP 2687. Grain yields were estimated as 3689 kgDMlha (4242,35 kg/ha at

15 % moisture content) for UP 2338; 4512 kg DM/ha (5188.8 kg/ha at 15 %

moisture content) for UP 2382 and 4556 kgDMlha (5239.4 kg/ha at 15 % moisture

content) for UP 2687. The average straw-grain ratios on dry matter basis were

calculated and found as 1.33 for UP 2338, 1.38 for UP 2382 and 1.41 for UP

2687.

The potential availability of straw refers to the straw mass available above a particular

height of cut for collection. It could be calculated by subtracting the straw mass

left as stubble from the potential straw yield. The amount of straw left as stubble

depends on the height of cut and the nature of dependence may vary from crop to

crop and vClriety to variety. The measurements of straw distribution along plant

height (Table 1) showed that the amount of straw in the lower portions of the

plants was significantly higher than that of top portions. In case of UP 2338, this

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Table 1 Straw availability at different heights of cut for wheat crop

(a) Variety UP 2338

Straw OM distribution along plant height, kg/ha Straw to

Rep. Length of segments of stalks, emGrain yield Grain

kg/ha0-10 10-20 20-30 30-40 40-50 >50

Total ratio

1 1047 967 792 708 561 857 4932 3421 1.44

2 1076 954 847 690 567 838 4972 3524 1.41

3 1063 889 807 671 573 834 4837 4121 1.17

Av. 1062 937 815 690 567 843 4914 3689 1.33

SO 12 34 23 15 5 10 57 309 0.12

Height of cut, cm

10 20 30 40 50 74

Straw loss as stubble, kg/ha

1062 1999 2814 3504 4071 4914

Maximum straw availability, kg/ha

4914 3852 2914 2100 1409 843

(b) Variety UP 2382

Rep. Straw OM distribution along plant height, kg/ha Grain Straw toyield, Grain

Length of segment of stalks, cm Total kg/ha ratio

0-10 10-20 20~30 30-40 40-50 >50

1 1253 1117 994 854 721 1255 6194 4597 1.35

2 1268 1145 997 841 732 1268 6251 4316 1.45

3 1276 1124 985 867 698 1297 6247 4623 1.35

Av. 1266 1129 992 854 717 1273 6231 4512 1.38

SO 10 12 5 II 11 18 26 116 0.05

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Height of cut, em

10 20 30 40 50 78

Straw loss as stubble, kglha

1266 2395 3387 4241 4958 6231

Maximum straw availability, kglha

6231 4965 3836 2844 1989 1273

(c) Variety UP 2687

Rep. Straw DM distribution along plant height, kg/ha

Length of segment of stalks, em Total

Grainyield,kg/ha

1

2

3

Av.

SD

0-10

1355

1307

1316

1326

26

10-20

1185

1152

1198

1178

24

20-30

1050

1044

992

1029

32

30-40

885

887

871

881

9

40-50

731

711

756

733

23

>50

1284

1270

1271

1275

8

6490

6371

6404

6422

50

4512

4268

4887

4556

312

Height of cut, em

10 20 30 40- 50 79

Straw loss as stubble, kg/ha

1326 2504 3533 4414 5147 6422

Maximum straw availability, kg/ha

6422 5096 3918 2889 2008 1275

amounted to 1062 kgDM/ha for the first segment (10 em from rootside) which

decreased to 567 kgDm/ha in the fifth segment (40-50 em). Similarly for UP 2382

and UP 2687 the straw availability in the first segment was 1266 kgDMlha and

1326 kgDM/ha but decreased to 717 kgDM/ha and 733 kgDM/ha in the fifth

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proportional to the height of cut. The relationship between the straw availability

and straw loss as stubble with height of cut is shown in Fig. 1. A best fit to data

points was achieved using a polynomial as follows:

(a) For UP 2338

Y = 0.6184 h2- 112.34 h + 4913.6 R2 = 0.9974 .... (4 )

(b) For UP 2382

Y = 0.6864 h2- 133.48 h + 6230.7 R2 = 0.9948 .... (5)

(c) UP 2687Y = 0.7419 h2

- 140.03 h + 6422.1 R2 = 0.9955 .... (6)

Where,Y = potential straw availability. KgDMlha andh = height of cut of crop, cm

WOO, I

to10701105(1403020

-+-Straw availability of UP 2687_ Straw availability. of UP 2382-.-Straw availability of UP 2338-+-Losses UP 2687-.-Losses UP 2382_ Losses Up 2338

10or£. ~ I

o

1000

1000

7000

t..101

6000

~-0;:::

g'tlOO~:a>4000os:g0 3000

~en 2000

Height ofcut, em

Fig. 1 Effect of height of cut on availabilty and loss of wheat straw as stubble

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Since all the varieties were medium tall and were having similar

characteristics, it would be better to develop a generalized model for straw

availability using all the three data sets. The average straw ayailability was

calculated for the three varieties and a generalized equation was derived which is

given below :

y = O.696h2- 129.74h + 5862.2

3.2 Effect of swath parameters on straw recovery

... (7)

The parameters of straw swath are the height, width and linear density of

swath. The evaluation of these parameters could contribute to the following

information:

i) Fluctuations of feed rate of straw collection machine. Which is related to the

linear density of swath and forward speed of machine as follows:

Qr = pv ..... (8)

Where,

Qr = feed rate, kg/s

p = linear density, kg/m and

v = forward speed, m/s.

It is obvious from Eqn. 8 that the variation of linear density of swath from

one meter to another should be responded by a spontaneous change in the

forward' speed of the machine to keep a constant feed rate. However, in

practice, the rapid changes in forward speed cannot be maintained.

ii) Assessment of straw losses caused by the pick up unit of collection machine.

iii) Assessment of effective straw availability for collection.

iv) Assessment of straw losses as stubble.

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3.3 Linear density of swarth

The distribution of straw mass along the ~wath has been expressed in terms

of variation of linear density in randomly selected length segments of swaths. The

length of segments was 15 m for all the varieties. The measured values of linear

density of swath are presented in Table 2.

The stubble heights of selected swath were 38 cm for UP 2338, 41 cm for

UP 2382 and 41 cm for UP 2687. The variations of linear density of all the varieties

have been illustrated in Fig. 2. The average percentage variation of linear density

with respect to the mean value was found as 28.25, 24.81 and 32.08 % for UP. .

2338, UP 2382 and UP 2687 varieties, respectively. When these variations were

Table 2 Variations of linear density of swath after combine harvesting

Swath Linear density, kg DMimSegments*

Up 2338 UP 2382 UP 2687

1 0.85 0.95 1.002 1.40 1.10 1.003 1.05 0.65 1.254 0.80 0.55 1..155 0.30 1.05 0.956 0.75 0.80 1.507 0.65 1.00 1.258 0.85 0.60 1.759 0.90 0.95 1.5010 1.00 1.10 0.5011 0.40 0.55 1.0012 0.65 0.85 0.7513 0.95 1.20 0.7514 0.80 1.00 0.5015 0.95 0.85 1.00

Average 0.82 0 ..88 1.06SD 0.2638 0.2111 0.3575

*Each swath segment had a length of 1m

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evaluated on the basis of the percentage changes from one meter to another, the

maximum percentage changes were found as much as 170.73 % in case of UP

2338,136.36 % in case of UP 2382 and 165.09 % in case of UP 2687. This

indicates that the feed rate of the straw collection machine may vary momentarily

from meter to meter by up to about 1.7 times in case of UP 2338 and about 1.65

times in case of UP 2687, respectively.

2.0 -I1.8

~ 1.6-"=£ 1.4<;j~

1.2ttl

'-0

C 1.0'(;j

~c:4) 0.8"0...«l4) 0.6:§

:E0.4 ICl

0.2

10.0

III UP 2338 1m UP 2382 lillUP 2687

~

I~

:1:: j~

~; 1~ :-;

~I

II 'I

~ ~:~ jj ~;

II

:.;

~~

!".';

II~:

IIH "

~] ">: ~: ;"; ,)~x i.

:.; j~ ij ., 11

II

::~ ::, ::

ii

:1!I I H:,.;

:~ ~1:':

Ii

,~.

I::

II

j~

f!~1

'1::

I!:.;

1~ ;<:.;:.;..

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Swath segments

Fig. 2 Distribution pattern of straw in swaths left behind a combinefor different varieties of wheat

While examining Table 3 it could be deduced that the number of locations

whose variations fall within a range of -50 % to + 50 % of the mean value are 12

which accounted for about 80 % of the total locations measured (UP 2338). In

general, this percentage ranged from 80 % to as high as 100 % of the mean value

in both the varieties. The knowledge of straw distribution in a swath is important

because it indicates the amount of variations that the baler will have to cope with

from meter to meter. Assuming the forward speed of baler as 3.5 km/h, cutting

width of combine equal to 4.5 m i.e. a swath width of 1.4 m and field efficiency of

baler as 75 %, the field capacity of baler would be about 1.2 ha/h. For the height of

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cut of 15 to 20 cm, the average straw availability would be approximately 5 t/ha or

a feed rate of 6 t/h. Therefore, a linear density of 1.72 kg/m should be maintained

for collecting the available straw. Referring to the Table 2 and assuming the

average moisture content of straw at the time of baling as 6%, it could be seen that

for UP 2687, the baler would operate at under load conditions in about 95 % of

area since there is only one location whose linear density is more than 1.72 kg/m.

The sources of variations of linear density are due to the variations in straw yield

across the field and field conditions such as presence of ridges, feld irregularities

and lodging of the crop. However, the factors related to combine operation are the

major sources of variations. These include the variations in width of cut, forward

speed and height of cut, which are governed by the operator.

Table 3: Frequency distribution of variations of linear density of swath

Av.Frequency distribution of variations

Cropp, Range of variations, % of average

kg/m 0-25 25-50 50-75 75-100 100-125 125-150 150-175

Wheat UP 2338 0.82 0 2 0 5 6 1 1

Wheat UP 2382 0.88 0 0 4 3 5 3 0

Wheat UP 2687 1.06 0 2 2 5 3 2 1

3.4 llaler losses

The baler losses were calculated from the effective straw availability and

the material collected by the baler. The losses were found to be in an increasing

order as the speed increases (Table 4). The loss was minimum as 83.23 kg/ha in

the lower speed of 2.96 km/h and attained a maximum value of 88.40 kg/ha at the

highest speed of 4.50 km/h. The losses due to increase in the forward speed was

found to be significant (p < 0.05). The reason for significantly higher losses may

be due to shattering of wheat straw at higher peripheral speed of the pick-up unit

of the baler. The average baler loss was found to be about 81.30 kgDM/ha for a

speed of 3.46 kmlh which was equivalent to about 4.22 % of the effective straw

available for baling. Bamaga (2000) reported a similar baler loss of 5.1 % in paddy

straw at a cutting height at 32 cm.

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Table 4: Effect of forward speed on baler losses

Speed,km/hBaler losses, kg DMlha

R1 Rz R3

Average

2.96 84.0 82.5 83.2v 83.23

3.46 84.1 81.5 78.3 81.30

4.5 88.2 89.4 87.6 88.40

4. CONCLUSIONS

The results obtained duting the course of this study are summarized below:

i) The average straw: grain ratio on dry matter basis for three varieties of wheatwas found as 1.33 for UP 2338, 1.38 for UP2382 and 1.41 fer UP 2687. Incase of UP 2338, the amount of straw found in the first segment (10 cmfrom root side) amounted to 1062 kgDMlha which decreased to 567 kgDMIha in the fifth segment (40-50 cm). Similarly, for UP 2382 and UP 2687varieties the straw in the first segment was 1266 and 1326 kgDM/ha butdecreased to 717 and 733 kgDMlha in the fifth segment, respectively. Thissuggests that the straw availability is not directly proportional to the heightof cut.

ii) The availability of straw for baling at 40cm height of cut by a combine wasfound to be 1409, 1989 and 2008 kgDM/ha out of the potential strawavailability of 4914, 6231 and 6422 kgDM/ha for UP2338, UP2382 andUP2687 varieties, respectively.

iii) The linear density of the swath in a combine harvested field varied from0.30 to 1.4, 0.55 to 1.2 and 0.5 to 1.75 kgDMlm in the case of UP 2338,UP2382 and UP 2687 varieties, respectively.

iv) At a forward speed of about 3.5 km/h and stubble height of 15-20 cm, thelinear density of swath was found to be about 1.72 kgDMlm for full loadingof the baler. However, under prevailing harvesting condition for cuttingheight of 35-40 cm, the linear density works out to be about 0.98 kgDMlm.Therefore, the baler will be always under loaded which could be overcomeeither by lowering the height of cut of combine or by raking the swaths in

windrows.13

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ACKNOWLEDGEMENT

The funds provided by National Agricultural Technology Project PSR No.

39 for this study is duly acknowledged.

REFERENCES

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