Generally, the first unit in a bale stacking line, a Stacked Bale Storage Conveyor accepts bale stacks from a clamp or fork truck and stores a specified number of stacks so that they can be processed. Lift truck approach is sensed by a magnetic loop sensor which readies the conveyor. Bale stacks are incrementally advanced by the conveyor and the drive is forward-reverse to ensure proximity of stacks and stack availability to the next unit in line. The conveyor uses three strands of H-78 chain. Drive size is generally 5 HP and the conveyor is provided with a safety fence to avoid bale stack tipping.

The Bale Stack Downender rotates the bale to a horizontal position and conveys it to the next unit in the system. It’s hydraulically operated with an integral 5 HP hydraulic power unit and is rotated on a pivot. This unit can also be used to increase the height of the bale line from the accept level as it rotates. The Downender is provided with side fences for safe operation. This unit is generally followed by a Dewiring Conveyor.

An alternative to the Downender is the Destacker. The Destacker is more compact than the Downender, but its cycle time per bale is slower. The Destacker uses a hydraulic operated clamp to lift the bale stack above the bottom bale which allows it to be conveyed onto the dewiring conveyor. After the bottom bale is conveyed out, the clamp lowers the bale stack to the conveyor, opens, and rises to lift the bale stack above the bottom bale again. The Destacker is totally enclosed by a fence for safety.

Manual dewiring takes place on the dewiring conveyor which generally follows the Downender. At the accept end, a bale cushion takes the bales one at a time from the Downender. The bales are on end in the Downender and must tip flat to the dewiring conveyor. The air cylinder cushion softens the tipping action. Dewiring conveyors generally use chain with spike attachments to elevate bales and allow wire removal. Also available is an optional air cylinder operated turntable, foot pedal controlled, that allows individual bales to be rotated for dewiring.

The next step in the bale line may be an accumulating conveyor, which stores de-wired bales. This conveyor steps and reverses to ensure close bale proximity while also making bales available to the next unit. Accumulating Conveyors are generally multi-strand chain conveyors and are the length required to store bales for the necessary time to allow operator flexibility. Bale presence or count is sensed by photo eyes. If a right-angle turn is required, air operated power jump rollers are used to move bales sideways onto the conveyor.