In a “real-world” setting, it will be very difficult to achieve JIT delivery of any raw material for 24/7 operation. All multibale handling unit concepts, must include some at-plant storage. Even when known quantities of feedstock are stored in a network of SSLs, and a Feedstock Manager is controlling the deliveries, there will always be random delays.

To give a frame of reference, an initial decision was made to include 2.5 days of at-plant storage in this example. This minimum may work in the Southeast United States where ice and snow on the roads is not typically a significant problem for winter operations. In the U. S. Midwest, more days of at-plant storage will be required.

A visualization of at-plant storage for the rack system concept is shown in Figure 13.12. The number of racks shown is not part of the “cost analysis” example given later.

The bale remains in the rack until processed — there is no individual bale handling at the plant. This is a very important aspect of any multibale handling system. This reduction in bale handling not only reduces cost, but also reduces damage to the bales. The integrity of the bales must be maintained. The reader should visualize a multibale lift of large rectangular bales when the strings on one of the bales “pop” and the whole lift comes tumbling down. The same problem exists when the wrap on a round bale fails.