Precision Roll-Up

Thoughtfully designed to check off every box on your wish list, the R300’s roll-up system is key to consistent quality, adaptability, and long machine life. The roll-up should be gentle on tender turf, yet robust enough to roll up even the stiffest of grasses. At the same time, the flap needs to be placed in a predictable, consistent position. In addition to this fundamental functionality, at FireFly we wanted our roll-up system to be adaptable to any condition without having to completely reconfigure the mechanism.

These lofty goals drove our uncompromising commitment to building a unique roll-up system that is extremely durable, simple to use, and easy to maintain. After extensive testing, we’re proud of the result—the quietest and most adaptable, durable, and consistent roll-up mechanism every built.

The R300’s roll-up starts with FireFly’s exclusive compound flipper. This is not just two flippers; it’s a complementary flipper system that works together synergistically. The flippers are spaced at exactly the right distance and on different rotational centers so that one flipper starts the edge, and then the other one helps curl it over on this uniquely designed mechanism to start a tight, consistent roll.

At the same time, this revolutionary flipper system is mechanically self-adjusting. As sod thickness changes, it always provides the proper lead-in to the roll-up ladder. The developing roll passes under a sensor that detects where the flap is. This innovative design delivers a very repeatable start of a roll, which anyone that has ever operated a roll machine knows is key to consistency.

The next segment of the roll-up is the flexible, passive roll-up. This unique rubber and stainless-steel section of the rollup is easily adjustable—without tools—to any type of grass, density, and strength. We opted for a much longer passive section than any other manufacturer to allow more gentle handling. The flexible belt with cleats cradles the roll, providing consistent, uniform contact without causing any tearing action. In addition, a series of sensors here help detect the edge of the flap for automatic adjustments.

Once transferred to the active rollup, the roll passes under more sensors that measure the roll—its shape, diameter, position, and length of flap. The computer then calculates how to finish the roll with precise flap placement.

Even as the roll may change length or thickness, the flap is very consistent without the need for adjustments. When you’re harvesting on a slope, the slope changes the angle of the conveyor, which could slightly affect the flap position, but not on the R300. It will still make a very repeatable roll from one end of the field to the other, even if the angle of the conveyor is changing because the field is on a hill.

Because the rollup is so precise, you can easily change the roll length. Say you’re cutting 60-inch rolls for one customer, and 48-inch rolls for another customer. Most times, the only setting you’ll need to change is your chop length.

The R300’s active section of the roll-up is another system driven by electric servo motors. The roll-up utilizes premium materials like polymer bearings and stainless-steel ladder cleats. There aren’t any metal-on-metal pivots clanking together here—just quiet, consistent motion. And smooth and quiet systems last longer.

There are no grease points anywhere on the R300’s roll-up mechanism. We use stainless-steel flippers, and all the joints on this roll-up use polymer bearings on stainless-steel pins. FireFly pioneered this in our industry, and we still lead the way in using this technology to its fullest extent. The result is incredibly low daily maintenance of this machine.

engineered polymer bearings on R300 roll-up