{"id":1056,"date":"2026-07-27T03:23:23","date_gmt":"2026-07-27T03:23:23","guid":{"rendered":"https:\/\/silage-baler.com\/application\/grass-grinder-machines-processing-hay-for-tmr-systems\/"},"modified":"2026-07-27T03:34:16","modified_gmt":"2026-07-27T03:34:16","slug":"grass-grinder-machines-processing-hay-for-tmr-systems","status":"publish","type":"post","link":"https:\/\/silage-baler.com\/ky\/application\/grass-grinder-machines-processing-hay-for-tmr-systems\/","title":{"rendered":"Grass Grinder Machines: Processing Hay for TMR Systems"},"content":{"rendered":"
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Dairy Equipment \u00b7 TMR \u00b7 Feed Processing<\/div>\n

How large dairy TMR operations are using hay grinder machines to convert round bales into consistent-particle ration components \u2014 and why particle length control matters more than most dairy farmers realise.<\/p>\n<\/div>\n<\/div>\n

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The Gap Between Baled Hay and TMR-Ready Feed<\/h2>\n

Total Mixed Ration (TMR) feeding has become the management standard for Australian dairies milking 200 cows or more \u2014 particularly in the Murray-Darling Basin’s irrigated dairy belt, the Goulburn Valley, and the large-scale dairies of SW Victoria. The TMR system’s nutritional advantage is that cows cannot sort the ration \u2014 all components are delivered simultaneously, ensuring every animal receives the formulated energy:protein:fibre balance regardless of individual preference. The system’s operational challenge is that every ingredient in the TMR must be at a particle length compatible with the mixer wagon’s ability to blend uniformly and the cow’s physiological requirement for effective fibre.<\/p>\n

Round bales of silage and hay are the most common stored roughage component in Australian dairy TMR systems. A standard 1.25 m round silage bale contains material at particle lengths ranging from 20 mm (fine-chopped silage) to 200 mm (long-stemmed silage from poorly conditioned crops). When this variable-length material enters a TMR mixer wagon, the long-particle fraction does not blend uniformly with grain, mineral, and protein components \u2014 it forms clumps that pass through the mixer without full integration, resulting in physical sorting by cows at the feed face.<\/p>\n

A grass grinder or hay processor \u2014 dedicated machinery that processes round bales through a hammermill or roller system before the material enters the TMR mixer \u2014 solves this problem by standardising the roughage particle length before blending. This article covers how grass grinder machines function in a dairy TMR context, what particle length targets are appropriate for different stock classes, and the EverPower grinder product suited to Australian large-dairy operations. For how consistent bale density in the round baler affects the consistency of material going into the grinder, our article on how dairy farmers use round balers to secure year-round silage supply<\/a> covers the upstream production decisions that determine grinder input quality.<\/p>\n<\/div>\n

\"9F-70<\/p>\n

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Why Particle Length Matters in Dairy TMR<\/h2>\n

The Penn State Particle Separator: What Dairy Nutritionists Measure<\/h3>\n

The Penn State Particle Separator (PSPS) is the standard field tool used by Australian dairy nutritionists to assess particle length distribution in TMR. It consists of three stacking sieves (19 mm, 8 mm, and 1.18 mm screens) plus a catch pan. A correctly formulated dairy TMR should have: 2 to 8% of DM on the top screen (>19 mm \u2014 the physically effective long fibre), 30 to 50% on the second screen (8 to 19 mm \u2014 medium fibre), 30 to 50% on the third screen (1.18 to 8 mm \u2014 fine particle), and below 20% in the catch pan (<1.18 mm \u2014 very fine or starch-rich).<\/p>\n

When round bale silage or hay with long-particle fractions (100 to 200 mm stems) is added to the TMR without prior processing, it can push the top screen fraction above 15 to 20% \u2014 far above the 2 to 8% optimal. Cows at the feed face select and eat the long-fibre fraction preferentially (or sort it out and leave it) depending on their individual rumen buffering needs, producing inter-cow variation in actual nutrient intake that the TMR system was designed to prevent.<\/p>\n

Effective NDF: The Fibre Quality Target<\/h3>\n

Long-fibre forage provides physically effective NDF (peNDF) \u2014 structural fibre that stimulates rumination and saliva production, maintaining rumen pH above the subacute acidosis threshold. The challenge is to maintain adequate peNDF content in the TMR without creating the sorting problem that comes from excessively long particles. The optimal solution is medium-length (8 to 25 mm) chopped roughage that contributes peNDF without sorting risk \u2014 precisely what a properly calibrated grass grinder produces from round bale hay or silage input material.<\/p>\n<\/div>\n

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The 9F-70 Grass Grinder: Specifications and Application<\/h2>\n

How the 9F-70 Processes Round Bales<\/h3>\n

The 9F-70 animal feed grass grinder machine<\/a> accepts whole round bales directly \u2014 the operator places the bale on the feed table using the farm’s standard loader, and the machine draws the bale through the processing chamber at a controlled feed rate. Internal hammers or rollers break the bale material down to the operator-selected particle length (typically 20 to 50 mm for dairy TMR applications) before the processed material is discharged into the mixer wagon or feed out conveyor.<\/p>\n

Key operational parameters: throughput rate of 3 to 6 tonnes of fresh hay or silage per hour, adjustable particle length from 15 to 80 mm through screen selection, PTO power requirement of 55 to 80 hp, and direct compatibility with the 1.0 m and 1.25 m round bale formats produced by the 9YG-1.0 and 9YG-1.25A balers.<\/p>\n

\n\n\n\n\n\n\n\n\n
Target Particle Length<\/th>\nScreen Setting<\/th>\nBest For<\/th>\npeNDF Contribution<\/th>\n<\/tr>\n<\/thead>\n
15\u201325 mm<\/td>\nFine screen<\/td>\nHigh-grain TMR, peak-lactation dairy<\/td>\nModerate \u2014 adequate for >50% NDF silage<\/td>\n<\/tr>\n
25\u201340 mm<\/td>\nMedium screen<\/td>\nStandard dairy TMR, balanced ration<\/td>\nGood \u2014 standard dairy target<\/td>\n<\/tr>\n
40\u201360 mm<\/td>\nCoarse screen<\/td>\nHeifer TMR, beef TMR, sheep roughage<\/td>\nHigh \u2014 maximum rumen stimulation<\/td>\n<\/tr>\n
60\u201380 mm<\/td>\nOpen screen<\/td>\nRoughage-only feeding, minimal sorting risk<\/td>\nVery high \u2014 for low-grain rations<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

When Grinding Is Worth the Capital Investment<\/h3>\n

At current equipment costs, the 9F-70 is financially justified for dairy operations processing 4 to 8 round bales per day (1,200 to 2,400 bales per season). Below this volume, the TMR mixer wagon’s own processing capacity (most modern mixer wagons with kicker rollers and knives can handle long-particle silage at modest inclusion rates without external grinding) is sufficient. Above 4 bales per day, the grinder’s contribution to ration consistency and sorting prevention becomes measurable in milk production uniformity across the herd and reduction in subclinical acidosis signs at the feed face.<\/p>\n<\/div>\n

\"Large-scale<\/p>\n

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TMR Management: How Grinding Fits the Dairy Day<\/h2>\n

The Grinder in the Morning Feed Preparation Sequence<\/h3>\n

On large Australian dairy operations, TMR preparation typically begins 2 to 3 hours before morning milking. The standard sequence on a grinder-equipped dairy: load 4 to 6 round bales onto the grinder feed table before mixing begins, process each bale through the grinder into the mixer wagon, add grain, protein, mineral, and liquid components to the wagon, mix for the specified mix time, and discharge to the feed face before cows return from milking. The grinder’s throughput rate of 3 to 6 tonnes per hour means a 1.25 m silage bale (typically 500 to 600 kg fresh weight) processes in 6 to 12 minutes \u2014 adding 30 to 70 minutes to the TMR preparation sequence depending on number of bales per mix.<\/p>\n

Integration With the Baling Programme<\/h3>\n

Grinding is most effective when the round bale silage going into the grinder has consistent particle length from the baling step \u2014 a baler that produces consistently dense bales with uniform silage particle size (from well-conditioned crops at correct moisture) delivers more consistent grinder output than one producing variable-density bales from over-wilted or under-conditioned material. The investment in quality at the baling stage \u2014 mower-conditioner, correct DM targets, LAB inoculant \u2014 pays forward into more consistent TMR particle length from the grinder and, ultimately, more consistent cow performance at the feed face.<\/p>\n<\/div>\n

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Frequently Asked Questions<\/h2>\n
\nCan the 9F-70 process dry hay bales as well as silage baleage?+<\/span><\/summary>\n
Yes \u2014 the 9F-70 processes both dry hay bales and silage baleage. Dry hay at 14 to 16% moisture produces a slightly dustier output than silage at 45 to 55% DM, and the particle distribution from dry hay tends to be finer (more hammer-shattered fragments) than from moist silage at the same screen setting. For TMR applications where silage and hay are both included, process silage first, then dry hay, and add components in the mixer in the order that minimises fines generation \u2014 wet ingredients last.<\/div>\n<\/details>\n
\nHow does particle length from grinding affect milk fat percentage?+<\/span><\/summary>\n
Milk fat is directly linked to rumen pH and rumination activity. Inadequate long-fibre in the TMR (NDF below 28% or peNDF below 18% of TMR DM) depresses rumen pH below 6.0, reducing acetate production and consequently milk fat synthesis. Grinding roughage to the 25 to 40 mm target maintains adequate peNDF for rumen health while eliminating sorting. Operations that switch from unprocessed long-stem silage to grinder-processed silage at the correct particle length commonly report 0.05 to 0.15 percentage point increases in milk fat test \u2014 recovered from improved rumen function rather than from changed nutritional inputs.<\/div>\n<\/details>\n
\nWhat maintenance does the 9F-70 require between seasons?+<\/span><\/summary>\n
Primary annual maintenance items: hammer wear inspection (hammers typically require replacement at 500 to 800 hours of processing time \u2014 check for tip wear and balance), screen condition inspection (replace any screens with tears or deformed apertures that allow oversized particles through), bearing lubrication at all greasing points (monthly during operation), and PTO coupling inspection before each season. Total annual service time: 4 to 8 hours for a well-maintained machine in commercial dairy use.<\/div>\n<\/details>\n
\nCan a grass grinder process round bales without a second tractor?+<\/span><\/summary>\n
The 9F-70 is PTO-driven, requiring one tractor to operate the grinder. A second tractor or loader is needed to place bales on the grinder feed table unless the grinder is co-located with the TMR mixer under a covered feed preparation area where the same loader can serve both tasks sequentially. Most large-dairy installations operate a dedicated feed preparation tractor on the grinder while the farm’s primary loader continues other tasks. For dairies processing fewer than 3 bales per mix, a single tractor alternating between loading and grinding is workable with 5 to 8 minutes of idle time per bale changeover.<\/div>\n<\/details>\n
\nIs the 9F-70 suitable for sheep TMR operations as well as dairy?+<\/span><\/summary>\n
Yes \u2014 the 9F-70 processes roughage for any TMR-based livestock feeding system. For sheep and beef cattle TMR applications, the coarser screen settings (40 to 60 mm) produce the higher-peNDF roughage that is appropriate for non-dairy ruminants where rumen pH management is less critical than in high-production dairy. Sheep TMR operations running 500+ ewes on total confinement systems are the primary non-dairy application for the 9F-70 in Australia.<\/div>\n<\/details>\n<\/div>\n

\"9YG-1.25<\/p>\n

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EverPower Baling Machinery \u00b7 Condell Park NSW 2200<\/div>\n

Discuss the 9F-70 for Your Dairy TMR Programme<\/h2>\n

Tell us your daily bale throughput, current TMR mixer wagon specifications, and particle length targets \u2014 we’ll spec the 9F-70 configuration for your feed preparation system.<\/p>\n

Request a Quote<\/a> About EverPower<\/a><\/div>\n
+61 2 9708 3322<\/a> \u00a0|\u00a0 \u2709 sales@silage-baler.com<\/a><\/div>\n<\/div>\n<\/div>\n<\/div>","protected":false},"excerpt":{"rendered":"

Dairy Equipment \u00b7 TMR \u00b7 Feed Processing How large dairy TMR operations are using hay grinder machines to convert round bales into consistent-particle ration components \u2014 and why particle length control matters more than most dairy farmers realise. The Gap Between Baled Hay and TMR-Ready Feed Total Mixed Ration (TMR) feeding has become the management […]<\/p>","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_et_pb_use_builder":"","_et_pb_old_content":"","_et_gb_content_width":"","footnotes":""},"categories":[35],"tags":[],"class_list":["post-1056","post","type-post","status-publish","format-standard","hentry","category-applications"],"_links":{"self":[{"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/posts\/1056","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/comments?post=1056"}],"version-history":[{"count":1,"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/posts\/1056\/revisions"}],"predecessor-version":[{"id":1058,"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/posts\/1056\/revisions\/1058"}],"wp:attachment":[{"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/media?parent=1056"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/categories?post=1056"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/silage-baler.com\/ky\/wp-json\/wp\/v2\/tags?post=1056"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}