When Fuel Is Expensive, Silage Becomes Even More Valuable
By Felipe X. Amaro, PAS, Ph.D.
Global Technical Support and R&D, Passion Ag
With diesel prices rising across Europe and North America, every stage of silage production now carries greater cost. Here are three practical ways to reduce fuel use while protecting silage quality and feed value.
Fuel markets have become increasingly volatile in recent months, with global energy prices responding quickly to ongoing supply pressures and geopolitical uncertainty.
In Europe, diesel prices are running around 20–35% higher than last season, while in the U.S., off-road agricultural diesel is commonly around $4.50 per gallon depending on region and supply. Across global agriculture, higher fuel, fertiliser and labour costs are increasing pressure on forage production systems and making every tonne of silage more expensive to produce.
That matters because silage production remains one of the most machinery-intensive operations on farm. Fuel is used throughout the process — from mowing, conditioning and tedding through to harvesting, haulage, packing and sealing. In many systems, fuel typically accounts for around 8–15% of total silage production costs, meaning recent increases in diesel prices can add roughly 4% to the overall cost of silage production this season in some regions.
In practical terms, every field pass, every trailer load and every hour spent harvesting or packing now carries more cost. It also means that once silage is in storage, it is worth more than ever, because more expensive fuel, fertiliser, labour and machinery have already gone into producing it.
Rather than cutting costs at the expense of output or forage quality, the better approach is to improve efficiency across the silage-making process while reducing avoidable losses.
Here are three of the most effective ways to reduce fuel use while still protecting silage quality and feed value.
1. Reduce unnecessary field passes
One of the simplest ways to reduce fuel use is to avoid repeated machinery passes that add cost without adding value.
Every additional trip with a tedder, rake or merger increases diesel consumption, labour time and machinery wear. In grass silage systems, excessive handling during wilting can also increase leaf loss and reduce forage quality. Even in maize silage and wholecrop systems, unnecessary movement and overlap still contribute to avoidable fuel consumption.
The key is not to under-manage the crop, but to ensure that every operation has a clear purpose.
Better planning of mowing dates, swath widths, harvest timing and machine logistics can often remove an operation altogether. Reducing overlap, avoiding unnecessary handling and improving field organisation are some of the easiest fuel savings available without negatively affecting fermentation, yield or feed value.
2. Improve harvesting and haulage efficiency
The greatest fuel demand during silage production typically occurs during the harvest chain — forage harvesting, haulage and silage packing — where high-horsepower machines are working continuously.
At this stage, even small inefficiencies can quickly translate into substantial fuel use.
Improving coordination across the harvesting system can deliver meaningful savings, including:
- Matching trailer capacity to harvester output
- Avoiding bottlenecks at the clamp, bunker or silage pile
- Reducing idle time for high-output machinery
- Minimising unnecessary haul distances
- Improving traffic flow around storage sites
Machine setup is equally important. Factors such as tyre pressures, ballast, knife sharpness, chop consistency, processor settings, trailer matching and engine loading all influence fuel efficiency.
A poorly coordinated harvesting operation wastes diesel quickly, particularly when large machines are left waiting or operating below capacity. Done well, improving harvest efficiency not only reduces fuel consumption, but also helps move forage more consistently from field to storage, supporting better consolidation and preservation.
3. Protect the silage properly in storage
This may not immediately appear to be a fuel-saving measure, but in a high-cost year it becomes one of the most important.
By the time silage reaches the clamp, bunker or pile, a significant investment has already been made in fuel, fertiliser, labour and machinery. If that silage is then lost through poor consolidation, oxygen ingress, secondary heating or visible spoilage, the farm has effectively wasted alot of that input.
That is why protecting stored silage belongs firmly among the top priorities.
Good consolidation, rapid sealing, effective oxygen exclusion and prompt repair of any damage all help preserve the value already invested in the crop. High-performance oxygen barrier films play an important role in reducing oxygen ingress and helping maintain silage stability during storage and feed-out.
In warmer regions particularly, managing oxygen exposure becomes even more critical, as elevated temperatures can accelerate spoilage and reduce feed stability.
Saving a few litres or gallons of fuel in the field is worthwhile. Preventing tonnes of silage loss in storage is often worth considerably more.
Final thought
When fuel is expensive, silage becomes even more valuable.
The most efficient forage systems are not simply focused on reducing fuel use per acre or hectare, but on ensuring that every litre or gallon used is converted into usable feed.
In practice, the biggest gains usually come from three areas: reducing unnecessary field passes, improving harvesting and haulage efficiency, and protecting silage properly in storage.
Done well, those steps can lower fuel use while safeguarding silage quality, feed value and overall return on investment.
About the Author:
Felipe Xavier Amaro, Ph.D., PAS,
Felipe is an expert in animal and crop nutrition, with a strong focus on innovation, sustainability, and on-farm profitability.
Based in Gainesville, Florida, Felipe leads Global Technical Support and Research & Development at PASSION AG.With a deep understanding of the science behind nutrition and a practical approach to farm performance, he plays a key role in driving product development and supporting customers worldwide.
Felipe holds a Ph.D. from the University of Florida and is a certified Professional Animal Scientist (PAS), reflecting his dedication to scientific excellence and real-world results.