Safety first: Forage harvesters and balers pose significant safety risks
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EmailForage harvester and baler safety is non-negotiable. For one 23-year-old, the risk and result were tragic.
In late summer of 2023, a 23-year-old farm worker was found entangled in a running baler—alone in the field, the machine still running. His death was preventable. This tragedy highlights a critical truth: forage harvester and baler safety are non-negotiable.
Spring and summer are the times when harvesting forages turn into a race between quality and quantity. Often this race gets squeezed into a small window of opportunity before a rain event can spoil forage quality and/or quantity. When this happens, farmers may start to hurry to beat the raindrops. In my experience as a Michigan State University Extension educator, when farmers feel a sense of urgency, this is when accidents may be more frequent. Small steps may be missed, and important safety steps skipped because rain is coming!
Forage production is done with powerful equipment that cuts, crushes, chops and compresses large volumes of material. Whether you are a large or small farm, you need to respect the equipment you work around. Do not become complacent and let your guard down when it comes to safety.
Let me encourage you—no, let me plead with you, to never skip the small steps to hurry and go faster. A farmer can go fast and be effective and efficient without being in a hurry. Recently, I was asked to review a Michigan State Fatality Assessment and Control Evaluation (MIFACE) investigation report about an incident involving a round baler. Let me relate the incident that happened on a Michigan farm in the summer of 2023 and had the worst result possible (Photo 1).
The MIFACE report stated, “Late summer, a 23-year-old male farm worker was employed to bale hay in a field leased by the hay owner. The hay owner asked the worker to bale the hay at a fixed rate per bale. Rain was predicted that day. The hay owner was not present when the worker started the job but spoke to him on the phone that night just after 8 p.m. After the phone call, the hay owner stated he texted the worker asking he call when he finished that field because there was another field to be done. The hay owner had called the worker while he was driving to the field from a location approximately 43 miles away.
“When the hay owner arrived at the field, the tractor was found stopped but running high idle with the baler engaged. A nearby resident came out into the field and told the hay owner he had seen the worker 15-20 minutes earlier. The baler service door was found open. The hay owner turned off the power take off (PTO). The resident observed red fluid on a tire. Upon cracking the door to the baler, the farm worker was found entangled in the machine and unresponsive with no pulse. Emergency Medical Services (EMS) were called at 8:44 p.m. and arrived on scene at 8:51 p.m. Death was pronounced at 8:58 p.m. Based on these facts, the time of the incident is estimated to have occurred between 8:20 p.m. and 8:30 p.m.”
Contributing factors (from MIFACE report)
- The PTO was not disengaged, and the tractor was running when the 23-year-old left the tractor seat.
- Time pressure due to the incoming rain and need to get the hay baled.
- Risk tolerance history of unplugging without disengaging the PTO and shutting down the tractor.
- Lack of manufacturer or aftermarket engineering controls to provide for safe unclogging without total shut down.
At the time of the incident, a half consumed open beer was found on the tractor with another in a cooler. Alcohol was not found to be a contributing factor. However, it is important to note that even a small amount of alcohol can reduce reaction time and impair fine motor skills.
Recommendations
- Disengage the PTO and shut off the tractor engine before inspecting, servicing or unplugging a baler. At an intake rate of 3-4 feet per second, reflexes of the worker cannot be relied on to safely perform, without injury, clearing or adjustment at the in-running baler pickup roller splines.
- Farm equipment operators should complete hazard recognition and control training for the equipment they operate.
- Do not use alcoholic beverages when operating farm equipment.
The sad thing about this incident is this is not the only time this type of tragedy will occur. Farm accidents happen across the United States every year. This is why farming is considered the second most dangerous occupation after mining. The societal costs are hundreds of thousands of dollars when you include the direct and indirect costs of a fatal occupational injury. Often, this leads to farm stress, which can show itself in the form of depression or suicide.
Farm accidents have great impacts on everyone involved. The impacts can be physical, emotional and monetary. The cost of cutting corners is too high. Prioritize training, enforce safety protocols and foster a culture where safety is not optional, it is essential. Every worker deserves to finish the day alive and well. If you or someone you know is struggling with stress, fatigue or burnout, reach out. Michigan State University (MSU) Extension offers confidential resources for mental health and farm stress.
Farmers…be vigilant and take farm safety seriously. Don’t rush. You can be fast without being reckless. Safety doesn’t slow down your operation, it protects it. Train your teams, respect the machines and never underestimate the cost of a skipped step.
No bale of hay is worth a life. Think safe, work safe, come home safe.
For more information
- Farm Injury Data – MSU Occupational and Environmental Medicine: Statewide tracking of occupational farm injuries and fatalities.
- Managing Farm Stress – MSU Extension: Tools and resources to recognize and respond to farm-related mental health challenges.
For more information, contact Phil Kaatz with MSU Extension at kaatz@msu.edu.
