A pioneering spirit , and root cause analysis identifies roller-chain as the future for the ultimate in reliability for silage wagons

Published 3rd February 2025
New Zealand

For 64 years Hustler has been a pioneer in the industry, built on a DNA of digging deep to understand the pains of farmers, then inventing bold solutions to overcome the cause of those pains. In more recent decades this included the introduction of roller chains in bale feeders, an innovation that was ‘overkill’ and polarising for some at the time but made sense to those sick of the frustrations of conventional round bale feeders…  fast forward 20 years, and now every bale feeder runs a ‘similar’ type of roller chain set up.

Was it as straightforward as just selecting a different chain type to what was traditionally used?

Now, jumping back 20 years (after having already pioneered the reliable Chainless round and square bale feeding system) the answers weren’t as simple, as result we wanted! “A simple, practical round bale feeder that didn’t derail”. We investigated and researched many options, including wire rope, rubber belting with steel lugs infused along with others. Through root-cause analysis, trial and error, testing, and determination to solve the reliability problems farmers were frustrated with, what we settled on, delivered the result we needed. This was the release of the SL350 round bale feeder, a product that change the industry for many years to come… 

The reinvention of the silage wagon!

When the time came to reinvent the silage wagon, having already been building the classic design, that of the original Roberston (a solid machine) which was acquired by Hustler in 2016 but having a first-hand glimpse into some of the challenges farmers faced with conventional silage wagons, we started with research to understand the biggest frustration in the industry. 

Some of the insights we picked up from large-scale farmers had a lot of similarities to the round bale feeder frustrations prior to the 2000’s which allowed us to draw on those earlier findings and 15 years of experience in fine-tuning roller chains in acidic applications.

As with any invention, it’s never as straight-forward as you think, and certainly not copy-paste! Yes there are some similarities, but there new challenges too, such as maize/corn juice. Having earlier developed the Combi CM (Chain machine) for this application from 2019 we drew on experience from this product, having proved a solid run, as with all inventors there’s always a better way and we found that covering the chains so that they’re not immersed in silage was a game changer in several areas, such as less material binding in sprockets, longer chain life, fewer adjustments, and less corrosion all advantages achieved only with a roller-chain design.

But wait, there’s far more to it, than this right? We can’t give away all the secrets, some of which include Hustler’s own bespoke chain development to take reliability and low maintenance to the next level. 

Here is some of the root-cause analysis we discovered! (hint) a breaking strain contest is NOT the answer 😉

  • The biggest frustration we discovered from farmers with the old-school link chain wagons (like the original Robertsons design, Hustler used to build) was derailed or broken chains.
  • We found that the cause of this was due to how quickly link chain wears and then the oversight in keeping chain tension adjusted correctly
  • We identified that the extremely high point loading (rod on rod) of link chain was the root cause of this – it was not the tensile strength/breaking strain or material of the chain
  • After testing a variety of options we found that the huge surface area of the roller pin chain significantly reduced: point loading, chain stretch, the need for adjustment (set and forget), and therefore derailed/broken chains
  • Derailing is the cause for broken chains, sprockets, and shafts. When you prevent the chains from derailing, breaking strain has little effect, they simply last forever even with the heaviest, and toughest loads. 

Fast forward to 2021… and Hustler released the EzFeed silage wagon range, a true game changer in reliability and ultra-low maintenance!

Hustler feedout wagons are the only wagons on the market with a 5 Year NO Bull warranty! Not only that, but our Puck Board flooring comes with a 10 year warranty! Why you might ask? Because thanks for our innovation, build quality, strength and testing we can stand behind our product for your peace of mind.  

We’re often asked, what are the pros and cons of each chain type? 

Hustler

Roller Chain Wagons

Link Chain Wagons
Less chance of derailing of chains Χ Prone to derailing
Less chain adjustment required  Χ Constant chain adjustment is required to prevent derailing
Large chain pin surface area reduces wear and stretch Χ Extremely high point loading of chain links requires massive chain-breaking strength to last
Lasts for years without stretching Χ Stretches very quickly 
Chain tracks straight even when loose Χ Derails easily when not tensioned
The bars sit on wheels (rollers). This significantly reduces drag and load on all drive systems, shafts, couplings, bearings, etc Χ Bars become clamped to the floor when under load which causes, high drag and extra wear on sprockets, and gearboxes and is even known to break driveshafts
Low friction, allows for loads to be ejected out of the rear of the machine Χ Requires an extra gearbox at the rear of the machine to reliably eject loads out rear of machine 
Chains protected under sides prevent silage build-up in chains, sprockets, shafts, and bearings preventing premature wear Χ Chains immersed in silage causes accelerated wear, and corrosion to chains, sprockets and bushings
Chains support bars in vertical and horizontal directions reducing bent bars, and allowing for a single-chain design for even more reliability and lower maintenance Χ Requires multiple sets of chains and extra short bars to prevent bars from bending. 
Allows for direct pull bars to prevent chain twisting Χ Twisting of chain underload in some designs accelerates wear
More forgiving on sprockets allows for free play  Χ Any free play results in chains being derailed
Χ Requires oiling No oiling needed
Bars are easily removed or replaced without having to separate the chain On some designs bars can be removed or replaced without having to separate the chain
Lowest cost of ownership  Χ Cheap initial purchase price

At Hustler, we’re a team committed to the pursuit of helping farmers & ranchers achieve more everyday. 

We’re rapt to see the larger operations are seeing the tangible benefits of the Hustler innovation and making the switch to Hustler. 

To find out how much an EzFeed forage wagon could be saving you talk to one of our field consultants or dealers