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Highlights

Physical scale models of a first-generation cotton module builder and module loader were used to determine the dry bulk density and module integrity failures for switchgrass modules.

Abstract. Physical scale models of a first-generation cotton module builder and a module loader were used to test three different switchgrass particle size distributions using various levels of moisture content, module fill layers, and number of tamps per layer. The objective was to determine mean dry bulk density of the quasi-confined biomass module and the propensity of module integrity failures during emptying from the builder and during loader operations. Model designs resembled prototypes for minimizing inadvertent module upset and reduced the required module contents by a factor of 141. Overall mean dry bulk density was 80.4 kg m-3. Mean dry bulk density increased with increased narrowness of the switchgrass particle size distribution from a forage harvester. Particle size and tamping response appeared to be a unique phenomenon that slightly affected mean bulk density. Results suggested that modules should be constructed using increased numbers of fill layers with uniform tamping of each layer with at least no skips in progressive tamper action. Overall, 33 of the 48 modules exhibited integrity failures at a rate of 69% failures.