McHale Fusion 3 Plus launch at the National Ploughing Championships 2013

McHale Fusion 3 Plus – delivers film on film technology

James Heanue Irish Sales Manager at McHale explained,

“Our product design engineers have been working on our film on film system for four years. Once farmers have experienced the increased silage quality which a film on film system delivers they do not want to move back to more traditional methods. Silage quality is improved and also for feedout it makes the job much easier as there is only one form of plastic waste to deal with. Using a film on film system eliminates the need to separate the plastic from the net wrap for recycling.”

The McHale Fusion 3 Plus is a machine which can apply plastic to the barrel of the bale instead of twine or net wrap. The advantages of this system are:

  • The replacement of net with plastic also forms part of the wrapping process and adds value by placing more plastic on the largest surface of the bale. Thus, improving the quality of the bale.
  • When plastic is applied to the barrel of the bale it can be stretched to approximately 20%. This stretch ratio is higher than what can be achieved with net wrap or twine and as a result the material is kept tighter which ultimately results in better shaped bale.
  • As the plastic is being stretched as it is being applied to the barrel of the bale it expels more air than net wrap would and as a consequence this results in better silage quality.
  • As plastic is used to both bind the bale in the bale chamber and to wrap the bale, during the winter on feedout the farmer will be left with one form of waste to recycle. Overall one form of waste results in feeding time being reduced.


Patented Technology

Over the last four years, the development of the McHale Fusion 3 Plus system has taken place in various countries and in different climates in order to encounter challenging conditions. A change in temperature and sun light could affect the chamber wrapping film, in that, as the day got hotter or cooler the film was either being overstretched or under stretched, and this in turn would cause reliability problems and result in inefficient use of the film.

McHale responded to this and developed a patented application system which adjusts the breaking force on the roll of plastic in-line with working conditions. This allows for a continuously variable stretch which can automatically adjust to changes in the daily climate without the operator having to adjust any settings.

The McHale patent film application system ensures consistent film stretch, reliable film application and delivers optimum bale shape and bale density. The system also reduces or eliminates the chances of film breaking due to overstretch on a hot day.

McHale Fusion 3 Plus – i Touch Control Unit

The i Touch Control Unit makes the McHale Fusion 3 Plus a fully automatic machine. The McHale “i Touch System” has a 7 inch touch screen colour monitor and a number of physical buttons which monitor and control the machine functions.

The i Touch monitor also features a camera to monitor wrapper operation. The camera can work in two ways:

  1. At any point in the cycle the operator can switch to camera mode to monitor the wrapper and rear of the machine.
  2. In automatic mode the camera will automatically come on the screen at a number of pre-determined points such as when the bale tip is pressed, when the bale transfer takes place and when the first layer of plastic are being applied to the bale by the vertical wrapping ring.

Net wrap can still be used if required

The McHale Fusion 3 Plus can revert back to the traditional method of using net wrap and the switch over process is very simple. If the operator is doing hay or straw the switch back to net wrap is simple and user friendly.

Chopper Unit

Over the last decade Fusion machines were supplied as standard with 23 knifes as standard. The chopper unit on the McHale Fusion 3 Plus is fitted with 25 knifes to give better chopping.

James Heanue -McHale Irish Sales Manager

“When ordering a McHale Fusion 3 Plus the customer has the option to upgrade the chopper unit on the machine to a selectable knife system, which provides 3 options, engage and chop with a bank of 12 knifes, or with a bank of 13 knifes. Should fine chopping be required the operator can choose to engage both knife banks, which will give a 25 knife chopper system – capable of delivering a chop length of approximately 46mm.


James Heanue “There are a number of Fusion 3 Plus machines at work across the world and the concept of film on film is growing quickly.”

James feels “The McHale Fusion 3 Plus gives contractors a way to offer a new concept and differentiate themselves from their competition by providing a product which can deliver better quality silage for the farmer.”

For additional information on the McHale Fusion 3 Plus Integrated Baler Wrapper , click here.