Tom is the fourth generation to farm at Oaremead Farm, nestled in the rugged landscapes of Exmoor. He manages 1100 ewes and 130 Angus suckler cows on a pasture-based system. In 2019, seeking a more efficient and sustainable way to manage his herd, Tom introduced bale grazing and began outwintering his cows. The early years of bale grazing revealed both benefits and challenges, particularly during wet weather and with high stocking densities. Noticing the soil damage caused by traditional ring feeders, Tom designed and built the Burge Bale Unroller (BBU), a solution that minimised soil compaction, reduced labour, and improved grazing efficiency. By 2021, the BBU had transformed his system, allowing him to keep his herd out longer, reduce costs, and enhance soil health.

This case study explores Tom’s journey, detailing the steps he has taken to adapt and improve his system, and the lessons he has learned from several challenging seasons on Exmoor.

Timeline:

2019 – We began bale grazing with the goal of extending our grazing period into November/December, and then housing the cattle for calving in January. Back then, we set the bales out in a regimented way: 1 bale every 10m, with a herd of 60-70 cows consuming 2 bales a day on deferred grass. Unfortunately, the weather in 2019 was terrible, and it created a lot of mess—especially with the high stocking density I had. (Check out the photos below!) The cattle came into housing looking well, but the field suffered, particularly around the ring feeders, where the cows really trashed the soil, damaging its structure. We had to plough the field to restore it.

2020 – We tried bale grazing again. Luckily, the year was drier, so the mess was half as bad as the previous year. However, we still had to plough and reseed, as using discs wasn’t enough to restore the field to its original state. The main issue remained the ground around the ring feeders. It was clear we needed to try something different if we were going to keep the cattle out for longer.

Spring 2021 – After researching different options, I came across bale unrollers. Being an engineer, I decided to design my own! With the help of a local fabricator, the first prototype of the Burge Bale Unroller (BBU) arrived on the farm.

Autumn 2021 – We used the BBU for the first bale grazing season, and it was a great success. The cows made no mess. We had about 70 cows on half a hectare, eating 2 bales a day. We were able to keep them out until Christmas, when we housed them for calving.

2022 – Another successful year of bale grazing with the BBU, and the results were exactly what we were looking for.

2023 – After two years of successful outwintering, we decided to change the system completely. We kept the cattle outside for the entire winter and shifted calving to mid-April. That year, we had 130 cows, split into herds of 70 and 50. For example the herd of 70 grazed half a hectare, with 2 bales of hay unrolled daily on fresh pasture.

These were our notes from the change of system:

• There was about 2500kg of dry matter deferred, and we shut the field from September to begin bale grazing on December 1st.

• It turned out to be the wettest winter we’d ever experienced on the farm, with 900ml of rain between December 1st, 2023, and April 10th, 2024.

• Despite the conditions, the cows thrived through the winter, even putting on weight, and calved very well.

• The land held up remarkably well. While it looked muddy at first, it soon recovered and greened up. We experienced phenomenal grass growth afterwards. Some of the early paddocks had about 120 days of rest, yet those grazed in February/March grew back at the same rate as the earlier paddocks, setting us up nicely for spring.

• The cows helped aerate the soil, breaking up surface compaction from previous sheep grazing. As a result, we saw consistent grass growth throughout the summer, allowing us to harvest good hay crops.

• I dug several soil samples in spring 2024, expecting the worst, but was amazed at the worm activity. I now check the soil regularly and see continued improvements.

• A few fields didn’t perform as well, as the cows made a mess quickly. We moved them on faster than planned. I’ve since learned that the lack of aeration in those fields was likely the issue—they didn’t absorb water well, like a sponge, so they didn’t recover as quickly. We hope to improve this with another year of bale grazing.

2024 - Looking forward to another year outwintering, we reduced our sheep numbers to outwinter full time, and grown our herd to 160, plus trying this year to also bale graze our R1 heifers out too.

Savings from Outwintering:

2019 – After factoring in reseeding costs, the only savings were in labour. If the field had needed reseeding regardless of bale grazing, the savings could have been higher.

2023/24 – Significant savings were made, once we started using a Bale Unroller and changed the system to out-winter entirely, calving in April:

• We used only half the amount of bales (all hay), placing them outside and ready for the BBU.

• No straw or bedding costs.

• No need to scrape, store, or spread dung, as the cows spread it themselves while grazing.

• Labour requirements were significantly reduced.

• We noticed the cows were fitter, calved outside with fewer issues, and had no health problems like scour or mis-mothering. Colostrum quality was excellent.

• We’ve experienced no disadvantages from shifting from indoor February calving to outdoor April calving.

• We avoided bad weather, and the cows calved onto grass that was already growing.

• We saved about £40k in costs last season by outwintering the 130-140 cows.

Interested in learning how to implement successful bale grazing this winter on your farm? Check out our step-by-step guide on the blog

 How I Manage Bale Grazing with the BBU:

• Once a week we set the next 7 days worth of grazing paddocks up with Kiwitech electric fencing– this suits our time/labour demands on the farm. The previously grazed paddock is back fenced so cows can’t go back over already grazed sections to protect the regrowth.

• Most of the bales are already positioned where the grazing breaks will be, as we place them out during the summer.

• We back the BBU up to a bale, load on the bale and unroll it in the current paddock.

• Occasionally, we need to bring a bale from another paddock. To make this easier, I designed the "fence hopper" addition to the BBU, allowing us to drive over the electric fences.

• If we only need part of a bale, we unroll what’s needed and leave the rest on the BBU for the next break.

• We’re prepared to unroll extra bales if the weather turns really cold or wet and the deferred grass isn’t enough.

• The key is not putting out the entire winter’s supply of bales at once. This year, we placed enough bales to last until roughly February. Then, during a frost, we’ll bring out the remaining bales to take us through to April. This approach helps minimize waste.

• We use Kiwitech drag troughs for water, moving them with the herd as they graze each fresh break. The trough is attached to a long 25mm pipe and is dragged across the field.

The Burge Bale Unroller (BBU) is available directly from Tom. It is specifically designed for use with your ATV/UTV. Built tough with a galvanized chassis and high-quality parts like a strong winch and T-Bar bale pins. It is adaptable with additional attachments such as a pipe winder and fence hopper. For more details, technical specification and prices click here.