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Innovative overhead loading and push-off technology saves time and money

Overhead Loading Technology from Fliegl

Harvest time is peak time for transport work. This is above all true for the transport of biomass. Fliegl Agratechnik GmbH, Töging, an innovative company for transport logistics has bought numerous inventions to the market in this sector. Martin Bauer, Export Manager at Fliegl, introduced “transport logistics for substrate preparation” in the framework of the “Bavarian Biogas Forum” in his presentation.

Martin Bauer, Export Manager of Fliegl Agrartechnik GmbH: “Classic transport logistics are at their limits. At Fliegl we have solutions for the future”.

Small biogs plants of up to about 250 kWel with about 6000 tonnes of chopped material per year and corresponding quantities of fermentation remains do not require extensive preliminary planning, to organize the transport. Either using their own machinery or having it professionally organized is enough for classic transport logistics: Forage harvesters, tractors with trailers and liquid manure tanks in the fields and on the roads, which are using diverse distribution and collection technology.

Classic transport logistics controls everyone

Martin Bauer names the advantages and disadvantages of such classic transport logistics. In most cases existing vehicle fleets can be deployed. Tractors can be deployed in many ways. They do not need to be fitted with tachographs. The work-flow of harvesting and distribution of liquid manure or fermented residue are known to farmers. Specialized personal are not needed for planning such relatively easy logistical undertakings.

The disadvantages of classic transport logistics becomes apparent in the case of increasingly larger biogas plants. The transport amounts and the distances increase. Classic transport logistics can no longer cope with the substrate quantities. Transport times increase. More trailers are needed. Traffic increases. On long transport routes there are problems with tyres on fields.

Combined transport needs specialists

Not so with “combined transport”, a logistic system to cope with larger transport volumes and greater transport distances. The transport procedure “combi-transport” increases the performance with the harvest, improves economy and raises profitability. It prevents large traffic loads and protects the soil. Areas can be cultivated in a more sustainable way. Energy can also be saved during transport.

“The transport procedure “Combi Transport” requires a specialization of vehicle fleets by the operators” says Martin Bauer. The HGVs do not need to be fitted with tachographs. Specialist personnel are needed. The planning and organizational work required is very high. Work-flows are rigidly structured and have little room of error.

Early Planning

According to Bauer the most diverse points should be considered. Planning for trnsport logistics should already begin in the spring with the sowing of the seeds. Through the sowing of early and late ripening varieties the chaff and the transportation dates can be set. Martin Bauer “This extends the harvest time, evens out the traffic volume and reduces inconvenience to local residences.” It goes without saying that sowing and weather conditions must be taken into account. With a multitude of suppliers, a high number of fields, increasing tonnage and more vehicles in use, risks from the weather and road hazards has increased considerably. “Not every situation can be planned for. Alternative plans and emergency plans, already under consideration should be implemented”, says Bauer.

Digital field maps, of the type that can be installed on any suitable computer with the relevant software, can be very helpful. In the case of complex and difficult transport logistics it recommended to refer back to mobile geographical information systems (GIS), in order to control the operation of the machines, tractors, transporters and HGVs.

Invoicing according to weight and dry mater

It is not common practice everywhere to record and settle the cost of biomass substrates according to the delivered fresh mass and its dry matter content. Martin Bauer “In cases where the cost is settled according to weight, the security increases and with this the trust.” The invoicing should, in any case be transparent and easily understood. The same is true for the pricing of harvesting technology and transport, which is calculated according to hectares, hours or weight, or a mixture of these.

Overhead loading is the crucial factor

„Kombi-Verkehr“. Farmers and clever businessmen reorganize the logistics of conventional straw crop harvesting operations. Fliegl Agrartechnik GmbH, Töging, supports them with the mobile overhead loading station, “SpeedStation” and with push-off trailers that are either equipped with high power overhead loading belts or overhead loading augers.

They crucially improve the logistics of different straw crop harvests. The overhead loading station which can be quickly set-up on the edge of a field, in any location, is the hub, connecting link and buffer of the transport process “Combi Transport”.

This is the main advantage of the Fliegl SpeedStation says Bauer: "The Speedstation" to improve the soil. It Improves the power of the harvesting process, improving the efficiency and adds substantially to the profitability of biogas plants, and that is what matters".

The Correct Transporter

In the future the flow of the harvested goods will be seamlessly documented. The documented data can be called up on a Touchscreen based on an ISOBUS system .

The explanation for this: “Agricultural transporters will be exclusively used in the fields from now on.” The harvested goods will be loaded into the reception bunker of the overhead loading station. From here it is loaded fully automatically into the HGV, which is parked on solid ground. Export manager Martin Bauer: “The HGV can economically transport large quantities of the harvested goods at high speed to far off destinations.” HGVs no longer have to drive on the harvested fields. Because of this their high pressure tyres, designed for fast roads, no longer damage the soil. Transport from the field is taken over by soil friendly transporters such as push-off trailers and dumpers from Fliegl. There are no more deep tyre tread marks in the ground, which in the long term limits capillary action in the ground and damages the fertility of the topsoil.

Flexible use over the year

Die Überladestation lässt sich das ganze Jahr über flexibel einsetzen. Sie eiThe overhead loading station can be used flexibly over the entire year. They are also suitable for the loading of Nitrogen.

Innovative Construction

The mobile overhead loading station “SpeedStation” consists of a reception bunker with a wear-resistant moving floor, two hydraulically operated and drivable folding walls and a sloping conveyor. The lowering support foot and the rear axle, can also be operated hydraulically. Low pulling power Ideas and above all function make the Fliegl overhead loading station stand out. The moving floor of the input hopper feeds the sloping conveyor with the harvested goods in an optimized way. Two specially constructed height adjustable rotors loosen up the harvested goods. The overhead loading station is monitored at a control platform. Martin Bauer: “Only a relatively low exertion force is required for the operation of the on-board hydraulic equipped overhead loading station.” An old tractor with a power rating of 88 kW (120 hp) at the PTO shaft is easily sufficient to operate the “SpeedStation” via a standard universal shaft..

Flexibility Written Large

The construction of the overhead loading station allows it to be used all year round in agricultural and professional holdings, for example for the collection and loading of recyclable waste, which needs to be loaded and weighed on an HGV on a regular cycle. These include, among others the solid phase of fermented residue from biogas plants, pomace from fruit and vegetable juice producers etc.

Quick Upgrades

The retrofitting of the overhead loading station in the transport position is easy and takes place rapidly. The SpeedStation may be driven at 25 kph on any public road to the respective location where it is to be used. There is a TÜV data sheet for Germany. Equipped with 385/55-22.5 RE size tyres, an unladen weight of 10 tonnes, a length of 12.00 metres, a width of 2.95 metres and a height of 3.95 metres traveling on prepared routes and implementation at the place where it is to be used is no problem. In the case of low-loader transport, the transport height is reduced to about 3.40 m.

High powered overhead loading unit »MobilFast«

The Fliegl push-off trailer with hydraulically folding overhead loading unit "MobilFast" loads up the transporter and HGV with an overhead loading power of up to 300 m³ per min .

The Fliegl push-off trailer with hydraulic folding overhead loading unit is extremely powerful. The overhead loading volume of the hydraulically driven scraper floor with wear resistant flat link chains is about 30 m³/min. With a loading height of about five metres (depending on tyres) it quickly loads up HGVs standing on the road or on the edge of the field.

Swiveling overhead loading unit »MobilFlexible«

With a swiveling overhead loading unit, loading from three sides is possible with the Überladeeinheit "MobilFlexible" .

Fliegl hat das Überladen noch flexibler gemacht. „MobilFlexible“ kann in drei Richtungen geschwenkt werden - auch während des Betriebs. Neben großer Flexibilität punktet sie mit geringem Eigengewicht, geringem Kraftbedarf und hoher Verschleißfestigkeit. Sie kann an jeden Fliegl- Abschiebewagen „GIGANT“ montiert werden und eignet sich für die Überladung von Kompost, Hackschnitzel, Mais, Gras, Erde usw. Die Überladehöhe beträgt 5 Meter, die Überladeleistung ca. 10 m³ / min.

Overhead screw conveyor closes holes

The new design of high power overhead loading screw conyeyor Typ 600 (tube diameter 60 cm) complements the overhead loading in combined transport. Like the overhead loading station it closes a hole in the work chain on the one side between harvest and silage or extraction of compost or wood chips and on the other side remote transport of the respective harvest goods or products produced. Depending on the use and location, the overhead conveyor screw feeds the goods to the field edge on field tracks or on logging roads on HGVs for remote transport to flat silos, bunker cells or storage tanks for biogas plants.


Advantages : Farmers and energy authorities, contractors, transport agencies, compost businesses and sawmills, can use the original Fliegl push-off trailer for a variety of tasks all year round. It can feed many different and difficult to handle goods such as corn, grass, all types of silage, wood chips, without problems to a height of 5.30 metres. The even feeding of the product to the overhead screw conveyor at the rear of the overhead loading vehicle can be automated with electronic control. It regulates the feed of the sliding floor and prevents blockages on the distribution rollers and the feed screw conveyors. In this way the usual impact load on the power take-off shaft is drastically reduced.

Energy is also saved. As a result the overhead loading power increases. In practice very high unloading power has been measured, for example with wood chips up to 14.0 m³ per min, with grass silage up to 10.0 m³ per min, and with corn silage up to 12.0 m³ per min. The electronic control system (VarioSens ISOBUS) relives the driver: He is not required to continually control and regulate the flow of the goods to the distribution rollers, feed screw conveyors and overhead loading screws. The is done by sensors, that control the feed of the sliding floor via a regulator. The speed is reduced with higher density material flow and increased with lower density material flow. An on-board computer allows particular values to be input according to the material, which guarantees an even and continual feed to the feed screw conveyors and conveyor screw.

Push-off as Semi-trailer

For combination transport Fliegl equips its semi-trailers with its original push-off system.

With special one or two axle dolly systems HGV trailers can also be drawn by tractors, in this way a part of the bearing load of the trailer be transferred as bearing load to the tractor, aiding the overall traction.

The connection between Fliegl Dolly and Fliegl push-off semi-trailers makes biogas logistics more flexible and more economic.

Agricultural Truck for Field and Road

Faster on the road, quieter in the towns: The Fliegl “Agro-Truck” combines a four axle HGV with the push-off system from Fliegl.

Martin Bauer: “The concept combines the tempo of road transport with robust applications on the fields.” The basis for the “Agro-Truck” is a power and robust reinforced chassis of a Mercedes-Benz 4144 All wheel drive.

Fliegl mounts on this, as an interchangeable body, its push-off with a loading capacity of up to 43 m³.

The total technical weight is designed to be 37 tonnes. For use on demanding terrain Fliegl has equipped the rigid axles of the HGV with large sized agricultural tyres (up to 710/45R22.5).

A 435 hp diesel motor delivers the highest power requirement on difficult ground, that can even overextend tractors.

Fast, All-terrain and Economical

The “Agro-Truck” combines the advantages of a push-off trailer and an HGV, reliably takes care of the work in the fields and guarantees speedy delivery on roads and motorways (70 kph maximum allowable speed). The all rounder can also be used with slurry tanks and accessory equipment such as spreader mechanisms.

Practical tests have shown that the Fliegl “Agro-Truck” can reduce the costs of maintenance and repairs by up to 25% or even 30% for diesel. The “Agro-Truck” - flexible, powerful and economic. The specialist for biogas logistics

Fliegl and Unimog

Two originals intelligently combine in biogas logistics: The push-off trailer from Fliegl with a Unimog as the towing vehicle. The Unimog can travel faster than a conventional tractor, whilst at the same time using less fuel. With its own dumping body it is also able to take extra loads. Its application possibilities throughout the year are diverse, whether for road works or in winter service. To utilize the suitability of the Unimog on the motorways, Fliegl also delivers a push-off trailer with corresponding certification. Fliegl and Unimog have supplemented the push-off technology with a further interesting variation by combining the strengths of push-off technology with an economic and flexible towing vehicle.