TM
Calmer Corn Heads
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 and DECOMPOSITION KITS
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.
Kill Stop Exam
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 questions, call CALMER's at:
(309) 629-9000
Allen Barry testimony
“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
Knife roll drawing
Too much flute overlap.
Overlapping flutes
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
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.
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).
Time
Ozs. Of Trash
w/small
sprocket
Ozs. Of
Trash
w/ 8
Tooth
Ozs. Of
Trash
Reduced
TOTAL Trash
Reduced
1:45
6
13
7
54%
2:00
4
18
14
78%
5:00
15
32
17
53%
5:30
15
37
22
60%
TOTAL
40
100
60
60%
Step 2
Install CALMER™ 6-Tooth Gathering Chain Drive Sprockets,
and CALMER™ 9-Tooth Idler Sprocket
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.
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.
Overlapping flutes
Corn picked with straight fluted
intermeshing stalk rolls
The Solution-
Install Revolving Open Window Calmer BT CHOPPER,  or CRUSHER   Knife Rolls
The leading edge
out of the window
is now a Calmer BT
Crusher edge for
better wear ability
for todays tough
stalks
We have improved the CALMER BT CHOPPER!
"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
Calmer booth at Farm Progress Show 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 Evidence-
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.
  • The reduction in trash intake was visibly noticeable from the combine windshield and also
    confirmed by weight comparison test data.
  • In multiple kill stops on dry afternoons trash intake was reduced by 33-percent.
  • Harvesting speeds increased significantly.
  • There was no noticeable change in header loss.
  • Optimum stripper gap was 1 1/4-inch at the bottom and 1 5/16-inch at the top.
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
$12,400.00 in parts to improve your 893 with
hydraulic plates, 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
$3,000
$  900
$  900
$4,000

$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
More Tips
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.
REVOLVING OPEN WINDOW
309-629-9000
309-629-9000
The Problem Prior to Calmer Upgrade - Stalk Breakage
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 BT
Stalk Roll
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
REVOLVING WINDOW
2-Revolving Window BT  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
2-Revolving Window BT Knife Rolls
1-Hydraulic Left plate, 1-Manual Right Plate
2-6 Tooth Drive Sprockets
2-9 Tooth Idler Sprockets
2-48 Standard Length 48 Pitch
Gathering          Chains
CALMER BT CRUSHER
EXPERIENCE THE DIFFERENCE...

TRASH REDUCTION and DECOMPOSITION KITS
Calmer BT CHOPPER with
the spiral (front) cut off to
show the chopping action
If you have any questions, call CALMER's at:
(309) 629-9000
CALMER
Corn Heads, Inc.
3056 700th Avenue
Lynn Center, Illinois  
61262
EXPERIENCE THE DIFFERENCE...
JD 600 SERIES
CALMER BT
CHOPPERS ARE
NOW AVAILABLE
TO ORDER!
Step 1
Install CALMER™ Revolving Window BT "CRUSHING" or "CHOPPING"
Knife Rolls
CALMER BT CHOPPER   
®
CALMER BT CHOPPER   
or
Click here to
watch video
CALMER BT CHOPPER  Trash
Reduction/Decomposition Kit Brochure
®
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
THE CALMER BT CHOPPER MODES OF ACTION
During processing the 10
straight, razor sharp knife
edged flutes chop 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.
Processing
Receiving
Better Than A
Chopping Corn
Head!
CASE-IH 2200
SERIES CALMER
BT CHOPPERS
ARE NOW
AVAILABLE TO
ORDER!
home
trash reduction
corn heads
used corn heads
moving to 15" & 20" rows
agronomic research
about us
directions
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CASE-IH 2200
SERIES CALMER
BT CHOPPERS
ARE NOW
AVAILABLE TO
ORDER!
JD 600 SERIES
CALMER BT
CHOPPERS ARE
NOW AVAILABLE
TO ORDER!
TM
®
®
®
Click here to watch video

Marion Calmer
explains the Trash
Reduction Kit

Marion Calmer
explains the Trash
Reduction Kit
Click here to watch video
®
Heat Treat
Hardened!
Better Than a Chopping Corn Head!
Better Than a Chopping Corn Head!
Download Brochure Now
Turn Your JD Corn Head into a
CHOPPING CORN HEAD
®
stalk rolls
with
Turn Your JD Corn Head into a
CHOPPING CORN HEAD
with
stalk rolls