Distinct design characteristics can make a significant difference to the performance of a forage harvester in maize crops, suggests New Holland. CPM delves into the detail of the firm’s latest FR Forage Cruiser models to discover more.
“Large-diameter header drums make easier work of tackling tall, heavy crops.” SIôN WHITTINGHAM
By Martin Rickatson
When it comes to processing the high volumes of plant matter produced by modern maize varieties, rapid harvest progress depends on plenty of power. However, according to New Holland’s Siôn Whittingham, it’s far from the only feature required to process large tonnages with pace and precision.
From developments that minimise operator fatigue to innovations that reduce blockage risk, there are multiple other factors that can play a part in maximising productivity, he continues.
However, at the core is a requirement to balance cost, capacity and fuel consumption. And while there are higher horsepower machines on the market, New Holland’s FR Forage Cruiser range with maximum power outputs from 476hp to 911hp, is positioned where the bulk of UK forager demand currently lies.
POWER TRANSMISSION
“The key to getting the full productivity from a forager is about more than power itself,” says Siôn. “In terms of design and features, it’s about effective transmission of that power, and keeping the machine operating at its optimum and most efficient.”
He highlights that once in the field, that starts up front with the intake. “With a fully row-independent header on the FR, you can cut in any direction, simplifying the headland work when opening up fields and allowing the operator to pick the best harvesting direction for the field shape.
“Large-diameter header drums make easier work of tackling tall, heavy crops. Then, on the Pro series maize headers we now offer, newly-designed drum teeth combine with a new knife rotor to draw stalks deeper into the drum, for smooth feeding, while new dividers between drums minimise the risk of plants being pushed over before intake.”
Where daily output is concerned, header design is as much about transport ease as it is about intake, he suggests.
“Features that enable swift movement from field to field can make a big difference to daily outputs. As announced at Agritechnica, we’re introducing new solutions this autumn that fully automate the changeover between field and road modes from the operator’s seat.
“One, ComfortRide, is an integrated hydraulically-operated transport wheel which automatically moves in or out of place as the header is folded or unfolded. Then, ComfortProtect manages the folding and unfolding of side guards, and connection or uncoupling of header lights. This will help operators to significantly reduce set-up time.”
With crop stems cut and gathered, the next critical components for maximising machine potential are the feed rolls that provide a consistent crop flow to the chopping cylinder, says Siôn.
“This is aided by a wide feed channel – and here the FR has the widest on market. That not only maximises input, but also creates a wide crop mat ideal for full chopping efficiency.
“Whereas grass can be rowed up to create a consistent swath, maize crops may be thicker and thinner in different field areas. A hydraulic damping kit developed for the FR Forage Cruiser models compresses the incoming crop stream to smooth out any lumps from thicker crop areas, ensuring a consistent feed to the chopping cylinder – particularly in high-moisture crops where it reduces material slippage – and then onwards to the blower unit.”
SHEARBAR
An effective chopping cylinder works at its optimum partnered with a shearbar matched to its capabilities, believes Siôn. As such, New Holland’s universal HD shearbar is compatible with both grass and maize, and is made from a stronger, more durable steel to cope with the harsher material of the latter crop, he says.
“It keeps a cleaner cutting edge through the season, which ensures that chop consistency is maintained for longer.”
New Holland also eases the seasonal changeover between crops via the Variflow system, highlights Siôn. When switching from maize to grass set-up, once the crop processor is removed the distance between the chopping cylinder and the drum is reduced by 60%, an arrangement believed to reduce crop turbulence and material dispersal, thereby cutting blockage risk.
“The processor hinges on a pendulum – as one swings upwards, the other comes into place. In maize it rotates further up the crop channel and allows in the crop processor, while in grass it moves closer to the drum to remove what would otherwise be a dead zone. It’s another design feature that keeps the crop moving as fast as possible through the machine.”
To help operators to exploit the full potential of their machine, New Holland revealed a further technology development at Agritechnica 2025. The first of its kind in the industry, the new CropSpeed blockage detection and prevention system has been developed in-house at its forage harvester ‘centre of excellence’ in Zedelgem, Belgium.
This is based around a spout-mounted radar sensor that monitors the crop flow leaving the forager, detecting any change in its rate in relation to the forward speed of the machine. If crop flow slows below 10km/h, the operator receives a warning to reduce forward speed so the machine doesn’t become overloaded and susceptible to blockage. Should the crop flow rate drop below 6km/h, the system cuts the drive to the feed rolls, in much the same way it does should a metal object be detected at the intake.
“The principle is that this helps to reduce blockage likelihood and makes dense blockages far less likely to occur,” says Siôn. “In the event a blockage should happen, cleanout and work resumption will be far faster, as material won’t have had the chance to fully block the machine’s internals.
“The system also helps less-experienced operators drive more confidently, to help maximize output. It’s complemented by a further new feature for 2026 FR Forage Cruiser models, a water injection system that works throughout the crop flow channel to further enhance efficiency in crops producing sticky residues.”
Also unveiled at Agritechnica – where it received an Innovation Award Silver Medal from the DLG, the show’s organiser – New Holland’s ForageCam technology will be available as an option on FR Forage Cruiser models from this autumn. Designed to maintain consistent chop quality, it uses a spout-mounted camera that continuously analyses chopped maize crop flow, monitoring the percentage of fully-processed kernels.
“This information is used to continuously and automatically adjust the kernel processor to achieve the desired forage quality, which also helps to maximise the forager’s fuel efficiency and minimise wear. The operator enters into the machine’s IntelliView IV terminal the required minimum percentage of cracked kernels that are acceptable – most operators seek 85-90% – and the machine then continuously adjusts the crop processor automatically during work.”
Siôn highlights that maximising the percentage of cracked kernels is desirable beyond just digestion by cattle where livestock silage is being produced. “In the case of maize for AD silage, cracking of maize kernels is critical to the AD process, and this technology will help users to maximise breakdown of plant material once transferred from the clamp to the digester.
“That in turn maximises the gas yield they get from their crops, and so the efficiency they achieve from their digester.”
To further ease the operator’s workload, New Holland has also enhanced the performance of its IntelliFill automated trailer filling technology, which it claims allows hands-off spout adaption to trailer filling progress, even in particularly demanding conditions such as low visibility.
“It completely automates trailer filling over a 210⁰ arc, moving autonomously from rear to side filling as necessary, so full focus can be kept on the crop ahead,” explains Siôn.
“The system also has a new user interface that provides live feedback. A camera shows images of the trailer filling progress, overlaid with key system indicators that keep the operator informed of filling performance.
“With Power Cruise speed control, that enables the setting of a target speed at a minimum engine rpm and then loads the machine accordingly. Plus row-guide steering, ForageCam kernel processing and the blockage sensor, means machine operation is almost fully automated, which helps to maximise output and efficiency, and minimise operator fatigue.”
TURNING AGILITY
Siôn points out that this is enhanced further by CustomSteer technology. “Already established on other New Holland machines, this allows FR Forage Cruiser operators to set the ratio of the number of steering wheel turns required to take the rear wheels from lock to lock.
“This means swift turns can be made at the headland with minimal movement of the steering wheel for reduced driver fatigue and greater precision, while on the road the steering sensitivity can be restored to the standard level. The result is greater operator comfort, swifter in-field operation and maximum road safety.”
Beyond these on-board systems, New Holland is also increasingly equipping its forage harvesters with technology that helps owners and operators with ‘off-board’ decision-making, relating to management of the crop, field and machine during and after maize harvest.
A key example is NutriSense, its near infra-red (NIR) sensor technology. This allows users to continuously monitor crop dry matter, and the variations that can often occur with crops drilled on different dates and/or at different levels of maturity. If this should vary significantly within or between fields, clamping practices can be adjusted accordingly, with drier material tending to require increased consolidation to ensure the exclusion of as much air as possible, suggests Siôn.
This recently-updated system provides users with immediate on-the-go access to accurate data collected by the forage harvester, a feature which New Holland suggests can enhance both in-field on-the-day decisions, and, longer-term farm management strategies.
“The NutriSense technology is offered as a factory-installed option,” explains Siôn. “The information it gathers is instantly stored online for viewing, analysis and decision-making, via the new FieldOps farm management web and mobile platform.
“FR Forage Cruiser models are compatible with a new Connectivity Included feature, which enables subscription-free connectivity. This also works with IntelliField which provides real-time in-field data sharing capabilities for boundaries, guidance lines and coverage data when multiple machines are operating in the same field. Data transfer and the unlocking of IntelliField requires a single one-time subscription.
“In addition, there’s also now the ability to export individual field data layers from FieldOps for sharing with advisers such as agronomists, and to create field boundaries before starting work using satellite imagery. This minimises set-up time once in the field so that opening up the headland can begin as quickly as possible,” he concludes.
This article was taken from the latest issue of CPM. Read the article in full here.
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