Silage harvest is one of the busiest and highest-risk times of year on the farm. With heavy equipment, multiple workers and time-sensitive tasks all in motion, it’s essential to make safety a priority. According to Trent Dado, dairy consultant with GPS Dairy Consulting, and Kevin Putnam, Northeast Dairy Specialist with Pioneer, proactive planning and clear communication can significantly reduce risk throughout the process.
Put a Plan in Place
“Silage harvest can be a whirlwind,” Dado says. “One of the things that I really encourage producers to do is to have a pre-silage harvest meeting with a lot of their stakeholders, including the custom harvesters. Not everyone knows the layout of your farm or fields, so having a short meeting to discuss safety, clarify roles and talk through any potential problems early is worthwhile.”
Putnam agrees, stressing the importance of clear communication and strong leadership during harvest.
“There are a lot of different people involved during harvest, so you want to have one person in charge.” Putnam says. “This person should know what’s happening at the bunk, can direct equipment traffic and tell people where to go. Have someone in charge of the flow and synchrony to keep things safe and efficient.”
Respect the Road
Road safety during silage harvest is just as important as safety in the field, especially when there’s a steady stream of trucks and wagons hauling feed back and forth. Both Putnam and Dado say it all starts with clear communication.
“One of the things we often forget is that a lot of the custom harvester crews, especially their truck drivers, may not have been to all your fields before,” Dado says. “They don’t always know where that narrow driveway is or which field entrance is hard to spot over the hill.”
That’s why preharvest meetings are so important — to talk through those little things before they become big problems.
Dado encourages farms to walk through traffic flow and field access ahead of time, even if it’s just a quick map or meeting.
“Should we widen a field entrance this year? Do we need a sign posted at the top of the hill that says ‘truck traffic ahead’? Those things are simple but can make a big difference in keeping people safe,” he says.
Putnam agrees, adding that planning routes in and out of each field and the bunker helps keep things running smoothly.
“Some drivers might be part-timers or new to the crew. They need to know which road to take, which lane to pull into, how to get into the bunk and where to go after that,” he says. “If people are guessing, it slows everything down and increases risk.”
Both experts also recommend giving local authorities a heads-up before harvest kicks off.
“Letting local police or EMS know when and where you’re going to be hauling silage gives them a chance to put out a PSA or just keep an eye out,” Dado says. “They’re part of the community, too, and it’s one more way to avoid issues.”
Putnam adds reaching out to neighbors doesn’t hurt either.
“A lot of farms send out a short newsletter [to their community] before manure season just a heads-up that says here’s what we’re doing, why we’re doing it and when. There’s no reason you can’t do the same before silage harvest.”
He also notes the importance of setting expectations with the harvest crew.
“Slow down, wave and be respectful to your neighbors,” Putnam adds. “Even if you’re not doing anything wrong, how we’re seen in the community matters. It helps build trust and keeps the phone from ringing with complaints.”
Bunker and Pile Safety
Big machines, tight spaces and nonstop traffic make silage bunkers and piles one of the more hazardous spots on the farm during harvest. According to Dado, bunker safety starts with traffic flow, good communication and making sure the right people are running the equipment.
“Within the feed center, understanding how traffic flows is a big deal,” Dado says. “A lot of farms set up one-way routes — trucks come in one way and leave another. That helps prevent congestion and reduces blind spots. Adding mirrors around corners also helps drivers see what’s coming.”
When it comes to the pile itself, Dado emphasizes proper slope and technique.
“Generally, piles are safe as long as you’re keeping your slopes reasonable,” he says. “For both safety and feed quality, you don’t want anything steeper than a 3:1 slope. Go beyond that, and you’re at risk for rollovers.”
Operators should avoid filling higher than bunker walls and make sure they’re packing evenly across the face. Dado warns that some of the most dangerous spots are near the bunker walls, specially if they’re not packed well early on.
“People are afraid to get too close, so they avoid those edges, which leads to soft feed,” Dado says. “Then later, when they finally do get close to the wall, their tires slip and they can get stuck. That’s a really dangerous situation.”
Both Dado and Putnam agree clear communication with everyone on the farm, including outside visitors, is one of the most important ways to stay safe during silage harvest.
“One of the biggest safety issues we see is people showing up to the bunk, like nutritionists, seed reps or consultants, and no one knows they’re there,” Putnam says. “They show up to check processing or take a sample, but they’re not visible and haven’t told anyone. That’s a huge risk.”
Whether someone is coming to the field or the feed center, Putnam recommends they always check in with the person in charge before arriving and confirm where it’s safe to park and walk.
“If I’m going to a cornfield or the bunker, I ask myself, where am I parking? Am I out of the way? Can everyone see me? Communicating that you’re there and making yourself visible is critical,” he says.
Reducing Fire Risk Through Maintenance and Preparedness
With choppers and tractors running long hours in dry, dusty conditions, fire risk is always something to take seriously. Dado says it’s one of the biggest safety concerns during silage harvest, yet it’s something farms often don’t prepare for until they’ve had a close call.
“These choppers generate a lot of heat,” he says. “All it takes is one bad bearing or a spark and suddenly you’ve got a very expensive piece of equipment in flames and people in danger.”
To help prevent fires, Dado recommends blowing off the chopper at the end of each day to clear out debris, plant matter and dust.
“It’s simple, but it makes a difference,” he says. “A clean machine is a safer machine.”
He also stresses the importance of fire extinguishers, not just having them, but making sure they’re actually usable.
“Take the time before harvest to go through your equipment and check that those extinguishers aren’t 10 years expired,” he says.
Beyond equipment, it’s also smart to have a basic fire response plan in place.
“Know where your nearest water source is and talk with your crew about what to do if something happens,” Dado says. “Even letting your local fire department know you’re starting harvest can help. If they know you’ll have trucks and equipment moving around certain roads, they can keep an extra eye out or respond faster if something goes wrong.”
Don’t Overdo it When Covering the Pile
When it comes time to covering the pile, physical fatigue and heat can quickly create dangerous conditions, especially for those who aren’t used to that amount of physical labor.
“A lot of people helping throw tires or cover silage may not be used to that kind of work,” Dado says. “It’s usually hot out, and fatigue can set in quickly. Make sure you’re watching out for signs of exhaustion or heat stress.”
The combination of heat, heavy lifting and long hours can lead to dehydration, dizziness and muscle strain. That’s why it’s important to plan for rest breaks, provide plenty of water and consider assigning lighter tasks to those who need them. Dado recommends rotating crews and building in regular breaks to keep everyone sharp.
“Harvest is tough physically and mentally, so managing your team’s energy is just as important as managing your equipment,” he adds. “Well-rested crews make fewer mistakes and work more safely.”
Finish Strong with a Safe Season
Silage harvest doesn’t have to come at the expense of safety. With a little extra planning, clear communication and a focus on keeping people visible and informed, you can protect your team and keep things moving smoothly.
“Harvest can be fast-paced and chaotic, but when everyone’s on the same page, it doesn’t have to be dangerous,” Dado says. “Take the time to prep. Those little details can prevent big problems.”
Whether you’re managing crews, covering a pile or hauling feed across town, staying safe means slowing down just enough to make good decisions. And that’s what helps you finish this silage harvest season strong.
