Calmer BT Chopper® and Residue Management Upgrade Kits and Components

Calmer BT Chopper® Upgrade Kit

Get MORE than you bargained for this fall with Calmer's BT Choppers® and Residue Management Upgrade Kits

Don't pay the hefty price for a new OEM corn head when you can yield better results at a fraction of the cost by simply upgrading your current head with Calmer's patented BT Chopper® Replacement Stalk Rolls and Residue Management Upgrade Kits available for JD 40/90 and JD 600 series, Case-IH 2200/2400 series and CNH 96c, 98c, and 996 series corn heads. With Calmer's patented revolving window in combination with 10 razor sharp knives, Calmer's BT Choppers® chop, cut and shear cornstalks into confetti for truly unrivaled residue management performance.

Agronomic and Mechanical Advantages

  • Agronomic Advantages
    • Unmatched Residue Decomposition
    • Warmer Soils
    • Dryer Soils
    • Increased Earthworm Populations
    • Reduced Nitrogen Penalty
    • Easier Planting
    • Higher Yields
  • Mechanical Advantages
    • Compatible with all Tillage Systems
    • 25% Less Hp Needed than with Chopping Heads
    • Superior Cornstalk Flow to Engagement
    • Better Ear Separation
    • Less Tire Wear
    • Less Butt shelling
    • Increased Harvesting Speeds (Achieved through a combination of installing Calmer® products and proper combine settings)
    • Less Moving Parts
    • Less Weight
    • Lower Maintenance Costs

Here's How Calmer's Patented Products Offer Solutions to Your Common Harvesting Problems!

Problem Prior to Calmer Upgrade: No Feeding Chamber

Straight fluted stalk/knife rolls have too much overlap in the entry area. When rotating at normal speeds, these intermeshing flutes have no entry window, preventing the corn stalk from engaging easily with the flutes and causing early wear of the spiral and first 2-inches of flutes. This hesitation results in stalks and ears passing below the corn head without being processed, making the field look plucked, not picked.

No entry window makes it difficult for stalks to travel into the knife chamber and causes early wear on spirals and fist 2" on flutes

Straight fluted intermeshing stalk rolls result in a lack of stalk engagement

Solution: Calmer's Patented Open Window BT Chopper® Knife Rolls

Calmer's BT Chopper® is the only stalk roll on the market with shortened flutes that are timed to create 2, 4-inch open window feeding chambers that easily allow stalks into 10 razor sharp knives that chop, cut, and shear cornstalks into confetti for superior residue decomposition! The design of the BT Chopper® makes for longer stalk roll life, reduction of low ear snap, less bulldozing of ears, and 100% traction the first time a blade touches the stalk.

Calmer's patented open window easily allows stalks into the rolls, extending stalk roll life.

Calmer's open window easily allows stalks into the feeding chamber and engages them with 10 razor sharp blades


Problem Prior to Calmer Upgrade: Non-Aggressive Flutes Result in Long Stalks That Limit Residue to Soil Contact

Factory stalk rolls are knife to knife and utilize a 1/8" to 1/4" air gap between blades. This gap is too wide which results in a slow or late pull of cornstalks, especially on a damp or rainy day. As a result, the amount of cornstalks consumed through the rolls is less than needed. As a side effect, the gathering chain pushes and hair pins the top portion of the stalk between the stripper plate and row frame.

Corn stalks did not travel into the knife chamber, resulting in little residue to soil contact and a very slow decomposition rate.

Side-by-Side comparison 7 months after harvest shows OEM's lack of decomposition ability due to leaving longer stalks and failing to expose the pith

Solution: Calmer's BT Choppers'® 10 Overlapping Razor Sharp Flutes That Allow for Superior Residue to Soil Contact

Calmer's BT Chopper® Replacement Stalk Rolls have a revolving open window in combination with 10 razor sharp knives that chop, cut and shear cornstalks into 1 ¼" confetti like pieces. This results in superior residue to soil contact and decomposition speeds without the added cost and hp requirements associated with rotary bladed chopping heads.

The top pair of knives on Calmer's BT Chopper® maintain grasp and control of the cornstalk, while the center pair of knives chop, cut and shear the stalk simultaneously

BT Choppers simultaneously expose the pith and explodes stalk stubs for rapid decomposition


Problem Prior to Calmer Upgrade: Excessive Gathering Chain Speed Results in Large Piles of Fluff

With genetic enhancements, today's corn hybrids are taller and dryer and therefore more brittle at harvest time. Current corn heads utilize row units with speed ratios from the 1960s that used fast gathering chain speeds. These fast gathering chain speeds often cause the gathering chain lug to break or shear off the top half of the plant before the stalk rolls have a chance to pull it below the stripper plates. The gathering chain lug then takes the broken portion of the plant and pushes it into the cross auger, eventually resulting in a LARGE PILE OF FLUFF.

Large piles of fluff indicate that the gathering chains are running too fast and therefore causing hair pinning at the top of the stripping tunnel

Solution: Calmer's Patented 6-Tooth Gathering Chain Drive Sprocket (available only for John Deere 40/90 series corn heads)

Calmer's Patented 6-Tooth Gathering Chain Drive Sprocket slows down the gathering chain by a full 25% and reduces trash intake by an average of 60%! This allows the stalk rolls to make additional revolutions and make more of the plant disappear below the stripper plates before the gathering chain lug can break it off. We also recommend replacing the factory 8 tooth idler sprocket with Calmer's Patented 9-tooth idler sprocket to reduce wear on the idler block and increase the chain lug's grabbing ability in down corn.

Calmer's patented driver and idler sprockets help mitigate trash going into the combine and large piles of fluff from accumulating on the corn head

We converted half of our test corn head to Calmer's 6-tooh drive sprockets leaving the other half with the factory 8-tooth sprockets. On average, Calmer's 6-tooth drive sprocket reduced trash by an impressive 60 percent!


Problem for JD Corn Heads Prior to Calmer Upgrade: Straight Stripper Plates

The original straight stripper plates are not formed to match the natural shape of the bottom side of the corn leaf. During ear separation, the plant leaves are pulled downward past these straight stripper plates causing them to be unnecessarily torn from the stalk. Because these Straight stripper plates do not emulate the rounded butt of the ear, they cause significant butt shelling and fail to allow the ear to get close enough to the stalk rolls to pinch the shank. This results in the husk staying attached to the ear, sending both the leaves and ear into the feeder house, creating more material for the combine to handle.

Straight stripper plates cause the husk to stay attached to the ear, sending both into the feeder house

Factory straight stripper plates increase butt shelling

Solution: Calmer's Patented Multi-Zone Beveled Stripper Plates

Calmer's Patented Multi-Zone Beveled Stripper Plates are straight in the front retrieving area to reduce ear wedging and beveled in the stripping area to allow the stalk rolls to engage more ear shanks, husks, and leave, reducing trash intake by an average of 33%. These beveled stripper plates have a weld hardened surface for extended life.

Calmer's Multi-Zone Beveled Stripper Plates emulate the rounded butt of the ear, doing a better job of displacing the energy and reducing butt shelling

Calmer's Multi-Zone Beveled Stripper Plates push more kernels toward the cob, reducing butt shelling.


Problem for CASE-IH and CNH Heads Prior to Calmer Upgrade: Complete Front to Back Bevel

The original factory stripper plates are beveled all the way from the front to the back, which is not formed to reduce ear lodging in down corn.

Factory beveled edge stripper plates are not formed to reduce ear lodging in down corn

Factory plates are beveled in the front where they should be straight which causes ear jamming in down corn

Solution: Calmer's Patented Multi-Zone Beveled Stripper Plates

Calmer's Patented Multi-Zone Beveled Stripper Plates are straight in the front retrieving area to reduce ear wedging and beveled in the stripping area to allow the stalk rolls to engage more ear shanks, husks, and leaves. These beveled stripper plates have a hardened surface weld hardened surface for extended life.

Calmer's Multi-Zone Beveled Stripper Plates emulate the rounded butt of the ear, doing a better job of displacing the energy and reducing butt shelling

Calmer's Multi-Zone Beveled Stripper Plates are closer to the lug which causes them to be sheared and keep them from lodging, especially in down corn.

For more comprehensive information on our BT Choppers and Residue Management Upgrade Kits, feel free to call us at (309) 629-9000 or check-out our product brochures below.

Calmer Product Brochures

"I want to congratulate you on keeping me out of trouble. I signed up my son for the kit and he said it was some of the best money we have spent. It works great!"

- Paul Isringhausen, Jerseyville, IL