Preserving forage begins with cutting the plants when they have reached maturity but still retain high nutritional value. The high initial moisture content (75% to 80%) must be reduced significantly through curing. This is accomplished by allowing the hay to dry naturally in the field, often spread out in thin layers to expose the maximum surface area to sun and air.
Moisture reduction is necessary because packaging wet hay creates an environment where microorganisms and mold thrive. These organisms consume nutrients and generate heat. If the moisture level remains above approximately 20%, this heat generation can become self-sustaining, potentially leading to spontaneous combustion.
Farmers typically use a simple hand twist test to gauge dryness: if no moisture can be extracted and the stems break readily, the hay is dry enough for manual packaging. Once cured, the hay needs to be gathered into long, continuous rows (windrows) or piled into manageable heaps. This consolidation step, usually performed using hand tools, prepares the material for manual collection and bundling.
Simple Hand-Tying and Bagging Methods
For small quantities, basic hand-tying techniques create low-density bundles known as sheaves. This method involves gathering a manageable armload of cured hay and compressing it tightly by hand or with body weight. The bundle is then secured with several wraps of natural fiber twine or durable rope and tightly knotted to maintain compression.
These hand-tied sheaves are practical for quick processing but offer minimal density, requiring more storage space compared to machine-pressed bales. This technique requires only the hay, twine, and the operator’s strength, making it suitable when only a few animals need feeding or when the hay field is small.
Bagging Hay
A slightly more robust, yet still low-tech, alternative is bagging, which utilizes readily available containers like heavy-duty plastic trash bags, large burlap sacks, or empty feed totes. The hay is stuffed into the bag in successive layers, and manual pressure is applied to each layer to achieve compaction.
Compaction can be increased by using a stick or pole to tamp down the hay or by using the operator’s body weight, such as standing on the partially filled bag. While bagging provides a contained, easy-to-handle unit, the long-term storage of hay in impermeable plastic bags should be monitored closely for moisture accumulation or heat buildup.
Constructing a DIY Hay Press
To achieve higher storage density, manual efforts must incorporate leverage using a DIY hay press. A simple press creates a package much closer in compaction to a machine-made bale, significantly reducing storage volume. This leverage-based compaction also helps expel air pockets, limiting microbial activity and spoilage.
Building the Box Press
The most common design is a simple box press constructed from sturdy wooden planks or plywood. This box typically has three solid sides, a fixed bottom, and one side that can be opened or removed for insertion and removal of the compressed hay. Dimensions should be chosen based on the desired size of the final bundle, often mimicking a small, rectangular machine bale.
Operating the Press
Before loading, two or three strands of baling twine must be pre-placed within the press, running across the bottom and up the sides. This positioning allows the twine to be wrapped around the bundle after compression. The box is then filled with successive layers of hay, pushed down with a pitchfork or by hand.
Once filled, the compression mechanism is applied. This might be a long wooden lever hinged to a post, a heavy weight dropped onto a follower plate, or a manually operated hydraulic jack for the highest compaction. The goal is to apply sufficient downward force to reduce the hay volume by a factor of at least two.
After the desired density is achieved and held under pressure, the pre-placed twine is pulled up and securely tied around the compressed material. Once secured, the pressure is released and the removable side of the box is opened. The completed, compacted bundle can then be ejected, resulting in a dense, uniform package ready for stacking.
Handling and Storing Manual Bundles
Manual hay packages, even those made with a DIY press, are less dense than commercial bales. This lower density means bundles contain more trapped air, allowing for greater fluctuations in internal temperature and moisture content. Consequently, manual bundles require more storage space and are more susceptible to absorbing environmental moisture.
Proper stacking techniques are important to ensure longevity and minimize spoilage. All hay should be stored off the ground, ideally on wooden pallets or gravel, to prevent capillary action from drawing up moisture. Stacks should be built with small gaps between bundles to promote air circulation and allow residual moisture to escape.
Monitoring the hay’s internal temperature is particularly important during the first two to three weeks after packaging, when the risk of spontaneous combustion is highest. Uneven curing or poor compaction can lead to pockets of high moisture content, causing rapid heating. Farmers use a long metal probe or thermometer inserted deep into the stack to check for excessive heat, which indicates a potential fire hazard.