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| Today’s BT corn hybrids are taller, dryer, and more brittle at harvest time. |
| Maximizing Trash Reduction in three easy steps with CALMER's TRASH REDUCTION KITS |
| I am glad you've come to this portion of my web site. In case you are not aware of it, I am the farmer that invented the 15" corn head in 1995. Since that time we have been testing both red and green corn heads throughout the United States. What you are about to read is my train of thought on reducing trash intake at the corn head, which ultimately increases ground speed, reduces horsepower and fuel consumption and reduces grain loss. |
| Step 1 Install CALMER™ 6-Tooth Gathering Chain Drive Sprockets, and CALMER™ 9-Tooth Idler Sprockets |
| With genetic enhancements, today’s corn hybrids are taller and dryer and therefore more brittle at harvest time. Current corn heads utilize row units with speed ratios from the 1960’s that used fast gathering chain speeds. Using these fast gathering chain speeds to harvest tall brittle corn plants, causes the gathering chain lug to break off the top half of the plant before the stalk rolls have a chance to pull all of it below the stripper plates. The gathering chain lug then takes the broken portion of the plant and pushes it into the cross auger. When the cross auger conveys these broken portions of the corn plant to the center of the corn head, they collide and create a LARGE PILE OF FLUFF (see photo below right). The Evidence The first indication that the gathering chain was running too fast was confirmed during kill stops. Examinations of the large pile of fluff indicated it was composed mostly of the top portion of the corn plant broken off by the gathering chain lug. |
| The second indication that the gathering chain was running too fast was corn stalks hair pinning at the top of the stripping tunnel on a wet or damp day. This happens because the gathering chain lug forces the top portion of the corn plant over the row unit frame. The third indication that the gathering chain was running too fast was confirmed while harvesting down corn. We have noticed root balls being pulled out of the ground and dragged into the corn head because the gathering chain speed is faster than the ground speed. The Solution – Slowing Down the Gathering Chain |
| “The smaller sprocket slowed the gathering chain down and that helped – quite a bit with the trash reduction.” |
| Steve Hardy Walnut, IL |
| In multiple kill stops on a dry afternoon, the smaller sprockets reduced trash intake and stalk breakage by as much as 78-percent in SW Texas. Harvesting speeds increased by as much as 3 mph. |
| If you have any more questions, call CALMER's at: (309) 629-9000 |
| “I've been using Calmer's Trash Reduction Row-Unit Upgrade Kit system for years. It definitely reduces trash. No reason for gathering chain to go zing'in around at high speeds.” |
| Allen Berry, farmer/crop consultant - Nauvoo, Illinois - (217) 357-5362 Switched to 15-inch rows in 1996 Total acres - 1,400 |
| Too much flute overlap. |
| The Evidence Prior to Calmer Upgrade - These overlapping flutes spin at 800 RPM’s creating a wall of rotating steel restricting entry of the corn stalk. By examining used straight fluted rolls and straight fluted knife rolls, the first 2-inches of the flutes are worn out. The balance of the flutes indicates minimal wear. Stripper plate wear also confirms this theory. |
| Beaters rotating at high speed. Straw cannot engage with beaters |
| THE CALMER BT CRUSHER MODES OF ACTION |
| Receiving |
| During receiving the 1" window appears, and allows the base of the corn stalk to flow easily from the helical screw area into the knife chamber |
| CALMER™ Beveled Stripper Plates are designed to match the natural shape of the bottom side of the corn leaf and the butt of the ear and ear shank. This significantly reduces leaf and husk intake |
| I am really pleased with Calmer’s Trash Reduction Row-Unit Upgrade Kit. The kit took care of every problem we had. We installed Calmer’s Trash Reduction Row-Unit Upgrade Kit last season and it was the first season we had without stopping once to remove trash from the corn head. We wish we had installed it years ago.” |
| Gathering Chain Lug Timing: Standing Corn – Stagger Lugs for less aggressive gathering to reduce trash intake. Down Corn – Synchronize lugs to be horizontally opposed for more aggressive gathering and slow corn head speed down. Cross auger should be vertically adjusted to have a 1 ¾” clearance between auger flighting and tray. (See photo left.) This significantly reduces ear slicing which is a cause of cracked kernels in the grain tank and increases traction on trash. (You may need to increase the length of the slots in the end plate bearing hanger to allow for this adjustment.) Cross auger should be horizontally adjusted as close to the feeder house chain and rear stripper as possible, this will improve the transfer of material from cross auger to the feeder house chain thus reducing ear toss. |
| Feeder House Chains should be adjusted as close as possible to the cross auger, this also helps reduce ear toss. Sometimes we add a half link to extend the feeder chain length. Plastic Gathering Chain Paddles: Attached to the gathering chain lugs will improve gathering and conveying performance in down corn. Some reports also indicate improved performance in trashy conditions. Corn Head Angle should be between 23 and 25-degrees for optimum performance in both standing and lodged corn. Put the combine on a level surface then lower the corn head until the row unit frame is 2-inches off the ground. Then place a magnetic protractor on the stripper plate and read the angle. If the angle is too steep, pull the top of the corn head toward the combine or push the bottom out or a combination of both. Gathering Chain Tighteners occasionally lock up. This is caused when the spring vibrates and augers itself into the hole between the bolt and the flat strap. This can be fixed by adding a second washer at the bottom of the pipe spacer identical to the washer that is currently at the top of the pipe spacer. Apply Never Seize or lubricate the bolt threads for future adjustment. Opening Stripper Plates can reduce trash intake, but can also increase header loss. Normal settings are 1 1/4-inch bottom and 1 5/16-inch top. Case IH cross augers have 4-inches of flighting overlap in the center. JD Cross Augers have none. We believe that 4-inches of overlap increases traction and helps pull lose trash and fluff under the auger and into the feederhouse. A small section of flighting can easily be welded onto the cross auger flighting to create this overlap. Use reverse flighting on 30-foot split cross augers. In the past, split cross augers had no reverse flighting near the bearing hanger. Some older 12-row, 30-inch corn heads used rubber flaps and no flighting. The performance of those augers was poor. New replacement augers with reverse flighting can be purchased from John Deere (right-hand part #AH208489, LH part #AH208488). See photo left. |
| CALMER Corn Heads, Inc. 3056 700th Avenue Lynn Center, Illinois 61262 |
| Phone : (309) 629-9000 Fax : (309) 629-9001 Email : mcalmer@ calmercornheads.com www.calmercornheads.com |
| To slow down JUST the gathering chain, we installed the CALMER™ 6-tooth drive sprocket. This sprocket is 25- percent smaller than the factory 8-tooth sprocket allowing the stalk rolls to make additional revolutions, making more of the plant disappear below the stripper plate before the gathering chain lug can break it off. We also installed the 9-tooth idler sprocket to give more grabbing ability and to enable the use of the factory 48 roller gathering chain. We suggest that you continue to run the rest of the corn head at its normal operating speed. Calmer's smaller 6-Tooth Sprockets fit both 40 and 90 series JD heads. |
The Test Results
We converted half of our test corn head to the CALMER™ 6-Tooth Sprocket leaving the other half with the factory
8-tooth sprocket. We did multiple kill stops at normal ground speeds and bagged loose trash on both halves,
weighed it, and compared the difference. Reduction of trash intake was visibly noticeable from the windshield of
the combine and also confirmed by weight comparison test data (see photo - above and chart below).
We converted half of our test corn head to the CALMER™ 6-Tooth Sprocket leaving the other half with the factory
8-tooth sprocket. We did multiple kill stops at normal ground speeds and bagged loose trash on both halves,
weighed it, and compared the difference. Reduction of trash intake was visibly noticeable from the windshield of
the combine and also confirmed by weight comparison test data (see photo - above and chart below).
|
| Step 2 Install CALMER™ Revolving Window BT "CRUSHING" Knife Rolls |
The Problem Prior to Calmer Upgrade -
Straight fluted stalk rolls and straight fluted knife rolls have too much overlap in the
entry area. When rotating at normal speeds, these intermeshing flutes have no entry
window preventing the corn stalk from engaging easily with the flutes. This slight
hesitation gives the gathering chain lug an opportunity to break off the top portion of
the plant (see lower left photo). This excessive overlap also causes stalk breakage at
the nodes during lateral whip.
Straight fluted stalk rolls and straight fluted knife rolls have too much overlap in the
entry area. When rotating at normal speeds, these intermeshing flutes have no entry
window preventing the corn stalk from engaging easily with the flutes. This slight
hesitation gives the gathering chain lug an opportunity to break off the top portion of
the plant (see lower left photo). This excessive overlap also causes stalk breakage at
the nodes during lateral whip.
| stalk breakage |
| To Demonstrate To demonstrate this stalk roll problem, I turned a food mixer on high and held the egg beaters so they were horizontal. Then I took a plastic straw and while holding the straw vertically, I tried to make the straw enter the beaters from the end, like a corn stalk entering a corn row unit. The straw bent over and never engaged with the overlapping flutes of the egg beaters. This is a great visual of what happens when we try to pick corn with straight fluted intermeshing stalk rolls (see photos below). This is dangerous!!! Do not try this at home. |
| Corn picked with straight fluted intermeshing stalk rolls |
The Solution-
Install Revolving Open Window Knife Rolls
Install Revolving Open Window Knife Rolls
| During processing the 10 knife edged flutes crush, crimp, cut, and lacerate the stalk while maintaining traction. This prepares the stalk for accelerated decomposition to organic matter and humus. This helps to feed microbes, bacteria, fungus, and earthworms for improved soil health. |
| The Crushers are chrome plated for extended wear! |
| "I've been running Calmer's Trash Reduction Kits since 2004, and have never had to stop for trash. Never having to stop once in 5 years, I feel, has increased my ground speed 25%-30% due to the combine not having to sort through all that trash. It's incredible running 6 mph while picking 200 bu corn!" Mendell Elson -- Miami, MO |
| Marion demonstrating the CALMER™ Trash Reduction Row-Unit Upgrade Kit at Farm Progress Show Exposition - 2004 |
| Step 3 Install CALMER™ Beveled Stripper Plates |
The Problem Prior to Calmer Upgrade -
The original straight stripper plates are not formed
to match the natural shape of the bottom side of
the corn leaf. During ear separation, the plant
leaves are pulled downward past these straight
stripper plates causing them to be unnecessarily
torn from the stalk. (see illustration to the right)
Straight stripper plates do not emulate the
rounded butt of the ear and do not allow the ear
shank to get close enough to the stalk rolls to
pinch the shank. This allows the husk to stay
attached to the ear, sending the husk into the
combine, creating more material for the combine to
handle
The original straight stripper plates are not formed
to match the natural shape of the bottom side of
the corn leaf. During ear separation, the plant
leaves are pulled downward past these straight
stripper plates causing them to be unnecessarily
torn from the stalk. (see illustration to the right)
Straight stripper plates do not emulate the
rounded butt of the ear and do not allow the ear
shank to get close enough to the stalk rolls to
pinch the shank. This allows the husk to stay
attached to the ear, sending the husk into the
combine, creating more material for the combine to
handle
The Evidence-
Corn stalk leaves and ear husks are mixed in with yellow ears during
kill stop examinations.
Corn stalk leaves and ear husks are mixed in with yellow ears during
kill stop examinations.
The Solution-
Install Calmer™ Beveled Stripper Plates. These beveled stripper plates are longer to scoop up low hanging
ears in down corn. Straight in the front retrieving area to reduce ear wedging and beveled in the stripping area
to allow the stalk to engage more ear shanks, husks, and leaves. These beveled stripper plates have a weld
hardened surface for extended life.
Install Calmer™ Beveled Stripper Plates. These beveled stripper plates are longer to scoop up low hanging
ears in down corn. Straight in the front retrieving area to reduce ear wedging and beveled in the stripping area
to allow the stalk to engage more ear shanks, husks, and leaves. These beveled stripper plates have a weld
hardened surface for extended life.
|
| CALMER™ Beveled Stripper Plates emulate the rounded butt of the ear. This does a better job of displacing the energy which reduces butt shelling. |
Roger-Groton, South Dakota
| "At my farm, I estimate it will only take about 500 acres of harvesting to produce enough dollar savings in time, fuel, and grain to pay for the BT Crusher Trash Reduction Row-Unit Upgrade Kits..” |
Marion Calmer
| $Amazing Return on Investment |
| By making the smart choice and installing Calmer Trash Reduction Kits today - while harvesting 1000 acres of corn, and increasing your harvest speed by 2mph, you would enjoy a projected savings of: Harvest after Installation Savings 60 less combine tach hours @ $150/hour 600 less gallons of combine fuel @ $3.00/gal. 60 less man hours @ $15.00/hour 60 less grain cart tractor tach hours @ $50.00/hour 300 less gallons of tractor fuel @ $3.00/gal 60 less man hours @ $15.00/hour 1000 less bushels of combine separation grain loss @$4.00 TOTAL SAVINGS Harvesting Capacity @ 3 mph = 7 ac/hour with 20 ft. or 8 row/30 in. corn head Harvesting Capacity @ 5 mph = 12 ac/hour with a 20 ft. or 8 row/30in. corn head. The math is simple, you spend $7912.00 in parts to improve your 893 and Calmer projects your return on investment is $20,500.00 your very first year of owning your Calmer Trash Reduction Kits! You spend $0.00 your second year and your return on investment is again $20,500.00! So let Calmer help you make more money with less trash and less stress. Start saving money, call Calmer's today! |
$9,000
$1,800
$ 900
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$ 900
$4,000
$20,500
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$20,500
| "We installed a Calmer Trash Reduction Row-Unit Upgrade Kit and when the season was over, I realized I didn't stop once all fall. We binned 100,000 bushels of grain. When I look in the top of the bins, it's never been cleaner.” |
Doug Hawn - Scranton, Iowa
Converted his entire corn head with the Calmer
Trash Reduction Row-Unit Upgrade Kits
Converted his entire corn head with the Calmer
Trash Reduction Row-Unit Upgrade Kits
More Tips
On corn head adjustments and modifications
On corn head adjustments and modifications
| Thank you for viewing this portion of my web site. |
| Call me so I can help you make this trash problem go away. Let's put the trash on the ground, not in the combine. (309) 629-9000 |
| HYDRAULIC KIT |
| MANUAL KIT |
| Copyright © Calmer Corn Heads. All Rights Reserved. |
| Great Stalk Chop! |
EXPERIENCE THE DIFFERENCE...
| REVOLVING WINDOW CALMER BT CRUSHER |
309-629-9000
309-629-9000
| The Problem Prior to Calmer Upgrade - Stalk Breakage |
| Processing |
| Exploded stalk, laying over, and ready for over-wintering! |
| Manual |
| Hydraulic |
| stalk breakage |
| Beveled Stripper Plates |
| Straight Stripper Plates |
| Before ~ This side of field is with factory JD |
| After ~ This side of field is with Calmer Trash Reduction Kit! |
| Marion Calmer at Miami, MO Test Field 2008 |
| Verticle Splintering |
| Horizontal Laceration |
| "The improvement we experienced on our farms is dramatic! Far less crop trash being taken into the combine. No ears flying around and out of the corn head, and the stalks are sized better by the action of the revolving window since the stalks now exit the rolls at the top near the ski-slope. We were able to increase our ground speed and at the same time deliver cleaner corn to the elevator. We are brothers who farm together in the Paxton-Ludlow area with our JD 9610 with an 843 Corn Head." Dana Sauer (left) and Tom Sauer (right) Paxton, IL Ludlow, IL |
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| REVOLVING WINDOW CALMER BT CRUSHER |
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EXPERIENCE THE DIFFERENCE...
2-Revolving Window BT Crushing Knife Rolls
1-Manual Left plate, 1-Manual Right Plate
2-6 Tooth Drive Sprockets
2-9 Tooth Idler Sprockets
2-48 Standard Length 48 Pitch Gathering Chains
1-Manual Left plate, 1-Manual Right Plate
2-6 Tooth Drive Sprockets
2-9 Tooth Idler Sprockets
2-48 Standard Length 48 Pitch Gathering Chains
2-Revolving Window BT Crushing Knife Rolls
1-Manual Left plate, 1-Manual Right Plate
2-6 Tooth Drive Sprockets
2-9 Tooth Idler Sprockets
2-48 Standard Length 48 Pitch Gathering Chains
1-Manual Left plate, 1-Manual Right Plate
2-6 Tooth Drive Sprockets
2-9 Tooth Idler Sprockets
2-48 Standard Length 48 Pitch Gathering Chains
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| CALMER BT CRUSHER |
| CALMER BT CRUSHER |
EXPERIENCE THE DIFFERENCE...
TRASH REDUCTION KITS |
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Marion Calmer explains the Trash Reduction Kit |
Calmer Trash Reduction Kit vs JD |
Calmer Trash Reduction Kit vs JD |
Marion Calmer explains the Trash Reduction Kit |