The management and reuse of corn residues is one of the most significant challenges for cereal farmers. Olimac offers an integrated solution.
Field operations at the harvesting site cannot be summarised simply as threshing the grain using advanced equipment in order to achieve maximum efficiency, but also involve managing the plant residues produced by the machine, separating the valuable parts from the less valuable parts of the plant, which then remain on the field as waste. In this way, it is possible to reduce losses and waste production, improving the sustainability of both the operations and the product itself.
The DragoGT header with Olimac’s rake represents a real innovation in this sense, allowing farmers to integrate corn harvesting with residue management in a single pass, thanks to simple and functional technological solutions, reducing operating costs and improving the overall quality of the work.
Sustainable Waste Management
The swathing system integrated into the DragoGT header is a solution designed to optimise the management of plant residues during maize harvesting. This technology is designed to convey chopped stalks, leaves and other plant residues directly and efficiently into neat, well-formed and, above all, clean swaths. Unlike traditional swathing systems, which intervene later, once the residues have already been deposited on the ground, here the material is directed into swaths before it touches the ground, thus avoiding any contact with impurities such as stones, soil or other debris that could compromise its final quality and affect its destination or reuse. This is an undeniable advantage, particularly important when the biomass is subsequently used for energy, livestock or agronomic purposes, contexts in which the cleanliness of the collected material directly affects the yield and efficiency of the subsequent process.
This result is made possible by the transverse auger installed directly under the header frame. Thanks to its strategic position, the auger intercepts the freshly chopped plant residues and conveys them neatly towards the centre of the machine, forming a compact and continuous strip of material. This process occurs continuously during corn harvesting without interfering with the productivity or operating speed of the combine harvester. The material is then optimally prepared for subsequent collection by other equipment, such as self-loading trailers or balers.
The most innovative aspect of the DragoGT header with rake lies in the elimination of a subsequent, separate phase for arranging the residues discharged onto the field. With a single pass, the operator simultaneously collects and manages the waste biomass, achieving a double result in a single operation. This brings numerous concrete opeational advantages: the number of passes in the field is significantly reduced, resulting in time and fuel savings, but also in a drastic reduction in soil compaction, a crucial factor for the overall health and fertility of the soil over time. Added to this is a significant improvement in the overall efficiency of the harvesting site, both from a logistical and economic point of view.
A single machine, a single process, superior quality biomass: all this translates into more sustainable and profitable agronomic management.
Biomass quality and energy valorization
One of the most significant advantages of the swathing system integrated into the DragoGT header concerns the quality of the waste material that is deposited on the ground. As described above, thanks to the targeted and precise action of the auger, the chopped material, consisting mainly of corn stalks and leaves, is collected and neatly positioned in swaths without coming into direct contact with the ground. This technical feature, which is far from obvious, allows for an extremely clean product, free from contamination such as soil, stones or other foreign elements that could seriously compromise subsequent stages of use. This result has fundamental implications, especially when the residues are used for the production of biomethane, a biofuel obtained from the anaerobic digestion of biomass. In this process, the purity of the raw material is crucial: even minimal amounts of gravel or contaminants can irreparably damage the digestion plants or drastically reduce the quality and energy yield of the gas produced.
With the DragoGT header equipped with a rake, on the other hand, it is possible to preserve the integrity and purity of the harvested material, thus ensuring biomass suitable for energy valorization in accordance with the highest standards of efficiency and sustainability required in modern times.
The opportunity to transform plant residues from corn harvesting into renewable energy represents a significant leap forward in modern agricultural management, paving the way for the reuse of agri-food waste and the production of renewable energy. Not only does it reduce waste and add value to by-products that would otherwise be left in the field or managed at additional cost, but it also actively contributes to a more sustainable agricultural model, capable of generating additional income and reducing the environmental impact of crops. Every cubic metre of biomethane produced represents a clean and renewable resource that can be used to power agricultural vehicles, local distribution networks or be fed into the national grid, making a concrete contribution to the energy transition.
In addition to its use for energy purposes, the biomass obtained from harvesting can also be used as high-quality organic fertiliser, reintroduced into the fields to nourish the soil. This allows for the completion of a virtuous cycle: what the crop has generated as waste returns to the earth in the form of organic matter, improving soil fertility and reducing the need for chemical fertilisers. The result is a more circular and environmentally friendly form of agriculture, in which every step of the production process is designed to maximise efficiency and minimise waste.
Reduction of Soil Compaction
The use of the DragoGT harvesting header with integrated swathing system also brings tangible benefits in terms of soil structure preservation, an aspect that is too often overlooked but crucial for long-term agricultural productivity. Thanks to the simultaneous management of maize harvesting and residue swathing, the overall number of mechanical passes on the field is significantly reduced. In fact, it is no longer necessary to use a specific swathing machine afterwards, with all that this entails in terms of traffic and soil compaction.
This traffic optimisation has a direct and positive impact on reducing soil compaction, a problem well-known to farmers and increasingly receiving attention from the scientific community. Less compacted soil is more alive: its natural water absorption and transpiration capacities are preserved, facilitating moisture and nutrient penetration, air infiltration and, above all, the free and deep development of the roots of subsequent crops. The result is a more balanced growing environment, where plants can grow healthily and uniformly, with a greater ability to withstand increasingly frequent water or heat stress.
But that’s not all. Eliminating the separate raking step also significantly simplifies field operations logistics. Each stage of the work is more coordinated and less time-consuming, allowing for a more rational use of invested and consumable resources. The overall processing time is significantly reduced, as is the risk of having to work under challenging weather conditions that could compromise the effectiveness of the raking operation or further deteriorate soil conditions.
This rationalisation brings with it a significant reduction in fuel consumption, which is a considerable factor in terms of both operating costs and environmental impact. In a context where sustainability and competitiveness must go hand in hand, every litre of diesel saved represents a step towards more efficient and responsible agricultural management.
Marco Delmastro
