3.4. Modulization of bales

Individual handling of bales (round or square) is not cost effective because of long loading and unloading times. Several concepts for a multi-bale handling unit are being developed. A verified multi-bale system is not available at this time to use as an example.

Permission was received [67] to present a concept that is far enough along in development that some field tests have been done. The concept was developed by a consortium led by FDC Enterprises and is shown in Figure 8. The self-loading trailer loads six stacks of six large rectangular bales, referred to "6-packs," for a total load of 36 bales. The bale size is 0.91 m x 1.22 m x 2.44 m. The length of the load is 6 x 2.44 = 14.6 m (48 ft), the height is 3 x 0.91 = 2.74 m (9 ft), and the width is 2 x 1.22 m = 2.44 m (8 ft).

The trailer built to implement the concept [68] is shown in Figure 9. Estimated load time is 5

min, which is about the same load time for the cotton module (Figure 7). The 36-bale unit

can be off-loaded by the truck directly onto the conveyor into a bioenergy plant, or it can be off-loaded into at-plant storage to be used later, just as is done with cotton modules at a cotton gin.

A similar concept known as the "Rack System" envisions that round bales will be loaded into a rack in-field or at an SSL. This rack is lifted off a trailer at the plant, emptied as the bales are needed, and then returned to be refilled. The racks are cycled multiple times each week within the closed logistics system. Cundiff et al. [59] developed the rack system concept, and it will now be used as an example to illustrate how the principles required for a logistics system are implemented.

All the various concepts and options cannot be discussed. However, we will apply a specific example to help the reader think through a process of developing a logistics system. The selection of the "Rack System" for this example implies no criticism of other ways of implementing the multi-bale handling unit concept currently being developed.