Kernel processor kit by Horning MFG
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Horning kernel processor kit on pull-behind harvester

Soup Up a Brand New Machine or Your Current Model

Many Horning fans order their new pull-type forage choppers straight from the factory without a kernel processor. They love bringing their new baby into the field for the first time with processing power to burn. Or you can also get a thrill by revving up performance on your existing rig.

Looks Good, Works Better

Horning roll technology is essential, but those fine-looking beauties are tucked away out of sight. Looks ain’t everything, but this sleek unit doesn’t have anything to be ashamed of in that department either.

Horning kernel processor kit

Plug and Play Installation

Horning Kernel Processing Kits are turnkey packages engineered for simple installation to make your job easier. Bolt it into place and it will look like it was born there. Everything fits and all the components are field-ready—hook up the belts and starting rolling.

Workmanship We’ll Stand Behind

Precision-built, premium quality, powerful performance—we want this processor to be an asset that serves you with excellence through many harvest seasons. We stand by you with a one-year workmanship and materials warranty on the whole unit and a five-year unconditional warranty on the bearing housing and idler arms, to be sure that is true.

Horning kernel processor kit roll detail

Speedy Switcheroo

Forage season is short. Minutes are monumental. Clever engineering allows you to switch from corn to hay in minutes. Just remove the pan at the bottom of the processor, take off the belts, and you are ready to cut hay. It’s as simple as pulling two spring-loaded pins and popping it out.

Horning kernel processor kit detail

Serious Shafts, No Joke

Bearing the load inside the processor are two TG&P alloy shafts. These big, two-inch workhorses run smooth and true no matter the load. Horning shafts don’t have stepped milling for either bearings or pulleys. Too much depends on them being simply the strongest.

Horning kernel processor kit hardware detail

Heavy End Frames for Stability

Inside, the processor is built like a tank. Every aspect of the construction takes it to the max. The super-duty end frames give the whole unit excellent stability and consistency. Fifty years from now it will still be a heavy hunk of steel.

Horning kernel processor kit belt detail

Flex Champ

The suspension framework that holds the rolls is ingeniously equipped with spring-loaded tension. If a large piece of foreign material runs through the processor, this flexing action allows it to pass through without tearing things up.

Optional Haylage Shields

Optional Haylage Shields

Horning goes the extra mile to keep your equipment in top form. This haylage shield snaps under the roll to protect the roll from the pack and prevent rusting.

Powder Coated Finish

Perfectly paint-matched to your brand, the tough galvaneal steel external shields with powder coat finish looks great and protects against rust and flaking. The lines and decals match your machine, too.

Coated for Durability

Many parts and components are coated for extra-long life. All hardware parts are zinc-coated, and all shields wear a protected galvanneal undercoating.

Heavy-Duty Cast Bearing Housings

No give, just solid muscle. That was the vision of this design. And it works! Less than 0.03% failure rate. The premium quality custom bearing housings are just plain massive. They last for years, but if you need to replace them, it’s easy.

Unconditional 5-year warranty on bearing housing and idler arm.

Adjusts In a Wink

Roll adjustment is almost child’s play with the Horning processor. A simple taper block system easily moves the rolls in small increments. A few turns to the hex head adjustment bolt dials in the perfect gap for optimum processing action.

Roll Options

Extraordinarily capable.

Versatile takes on a whole new meaning when it comes to the range of roll options the Horning processor makes possible!

Sawtooth row detail

Sawtooth Roll

Studies have shown that in most applications, sawtooth roll configurations running at 30% to 40% differential are the most energy efficient with kernel processing scores topping the charts for premium forage digestibility. Four teeth per inch heat treated are standard for pulltype. Sawtooth rolls at the right configurations can offer excellent cost efficiencies in the production of high quality feedstuffs for Dairy or Beef.

Fibertech Chevron roll detail

Fibertech Chevron

Or… you can run Fibertech Chevron in either heat treated or chrome coating* for rolls that very well could outlast your machine! Take advantage of the patented Fibertech tooth design for unmatched performance in standard forage harvest applications. Fibertech can run at either a standard 40% speed differential or an optional 30% speed differential for customized applications. Four teeth per inch is standard on pull type machines. Custom tooth configuration available. Fibertech Chevron is great for snaplage or extreme processing. Try the Fibertech Chevron, you’ll be amazed.

Horning kernel processor kit belt detail

Full Access for More Elbow Room

We designed the access doors to “button down” tight and stay put while being easy to get in and out of. Need more elbow room? Remove the doors completely for wide-open access to the heart of the processor.

Premium belts.

Horning KP units come standard with premium kevlar belts which are 1.5 to 2x stronger than non-kevlar belts. This allows us to run only 4 belts on the processing unit for greater performance, greater longevity and less cost over the lifetime of the KP Unit. Premium belts also reduce mechanical failure due to belts to nearly zero.

We’ve Got You Covered

John Deere, New Holland, Case IH and more. We have units customized for most major makes and models of pull-type choppers.

Specs

New Holland

782-790   | 590lbs   | 3-belt drive
890-892   | 625lbs   | 4-belt drive
900-FP230   | 665lbs |   4-belt drive
FP240-FHX300   | 680lbs |  4-belt drive

John Deere

3940-55   | 750lbs   | 3-belt drive
3960-75   | 790lbs   | 4-belt drive

Additional Features

Easy Access for convenient belt removal
Removable pan to convert for hay chopping
Kevlar belts for maximum no-stretch life
2” TG&P alloy through shaft with no steps
Easy-open hood allows quick access to rollers for maintenance.
Clear installation instructions included with all kernel processor kits for simple customer installation.
Phone service for installation (if needed) included no extra charge!
Minimal process power requirement differences between ¾’ cut length with processor vs ⅜’ cut length with- out a processor

Figuring Speed Difference

There are two methods used in figuring the speed difference in rolls. Both differential calculation methods use the pitch diameter of the pulley as the basis for the measurement. Some brands figure it one way and some the other. Neither calculation is wrong. But it is important to know which way it is calculated so that you can be sure you are comparing “apples to apples”.

Figuring Speed Difference
(Notice that the greater the roll speed differential, the greater the gap between the results of these formulas.)
1

Horning Method (H Method):

(based on pulley pitch diameters)

Fast (small) ÷ Slow (large) = Subtotal - 1 = Answer

Example:

((5 ÷ 7 = .714) - 1) = .286

(or 28.6% speed difference)

2

Other Method (O Method):

(based on pulley pitch diameters) 

Slow (large) ÷ Fast (small) = Subtotal - 1 = Answer 

Example: 

((7 ÷ 5 = 1.4) - 1) = .40 

(or 40% speed difference) 

Brand Comparison
Features Competitor 1 Competitor 2 Competitor 3 Horning
KP Rolls Iron hardened steel Hardened Ductile Iron Hardened Steel Iron Hardened Steel (chromed options available)
Roll Teeth Straight tooth Straight tooth Sawtooth Hi-cap, Sawtooth & Fibertech
Roll Shaft 1 3/4" (non-replaceable) 1 3/8" (replaceable - half cost of new roll) 2'' chromed 2" TG & P Alloy materail (replaceable)
Bearing Housing Gray Cast (30k psi tensile) Gray Cast (30k psi tensile) Gray Cast??? (30k psi tensile) "Ductile Cast housing custom designed with SKF Inserts (60k psi tensile) Less than 0.03% Failure Rate (5-year warranty on housing)
Bearing Spacing Approx 5"" from roll end (shafts commonly break) approx. 2” 2” from roll end 2” from roll end
Foreign Object Protection (FOP) One Roll Spring Loaded Both Rolls Spring Loaded Both Rolls Spring Loaded Both Rolls Spring Loaded
Roll gap Adjustment No Info Add and remove shims Taperblock Easy-adjust Taperlock
Removable Shield (switch frowm corn to hay) Bolted in place Bolted in place Spring loaded pins 2 spring-loaded (SS spring)pins for quick, easy removal
Processor End Frames 1/4 thick 1/4 thick 3/8" thick 3/8" thick
Exterior Finish Painted Painted Powdercoated Powder Coated. Galvanized Undercoat on exterior shields
Drive System 4-Belt Banded Belt & Flat Pulley 4- belt Special High-strength, Double-sided Kevlar Belts
Power Requirements Average High Power Req. – Due to Poor Roll Angle – Some Crop Misses Roll & Gets Re-cut Average Lower Power Req., Optimal Roll Angle, Efficient Processing
Knife Access Difficult to Access Easy Access Easy Access Easy Access
Speed Differential (see page 23) 15 -25% H-method, 17.5 - 34% Figured O-method 18% H-method, 21% Figured O-method 31% H-method, 44% Figured O-method 30% or 40% Figured H-method, 43% & 66% O-method
Optional Haylage shield No No No Yes

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