Off Paddock Insights - Edition 1

Edition: 01

Off Paddock Insights Keith Woodford: Composting Barns Require New Thinking.

• Solar-Powered Cow Barns: Self-Sufficient Energy Solutions • Case Study: New Feed Pad Surface with flood wash for Jersey Girl Farm • Case Study: Borries' Feed Pad in Waitaki • Exclusive Interview: Greg from Entegra on Ridgeback Barn Designs

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CONTENTS Keith Woodford: Composting Barns Require New Thinking.

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Solar Panels on Cow Barns: Is Self-Sufficient Energy Possible on NZ Dairy Farms?

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New Feed Pad Surface with Flood Wash for Jersey Girl

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Customer Case Study: Borries' Feed Pad in Waitaki

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Open Day Highlights at Borries' Feed Pad.

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Revolutionizing Dairy Barn Design: An Interview with Greg McCalman from Entegra 14

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Composting Barns Require New Thinking.

Article by Keith Woodford.

Composting barns require new thinking about managing the dairy system. It’s not just a case of sticking up a shed and then sitting back and watching additional milk and dollars flow.

Whenever I discuss composting barns with prospective farmers the first thing I want to know is why do they want a composting barn. How do they think it will make their farm more efficient and how will they measure this efficiency?

There are lots of valid reasons to build a composting barn.

In Southland it might be to solve the problem of winter mud and associated animal welfare. In Canterbury the key driver might be the need to reduce nitrogen leaching and the cost of off-farm wintering. In much of the North Island, the primary objective might be to deal with summer feed shortages rather than winter issues.

For one South Island farmer I regularly visit, it is about achieving a low-cost system that is resilient to both environmental issues and milk-price downturns. He achieves this by wintering all stock on farm with the aid of a composting barn, hence having no off-farm wintering costs, and only needing to feed eight kg dry matter of silage per cow per day during winter. This is also a very labour efficient farm with a focus on worker welfare. On this farm, the weekend winter work day, or indeed any winter work day can be over by mid-day regardless of the weather.

The cows can be observed 24/7 by camera from the dining room table.

Benefits can come from unexpected outcomes. For example, farmers and their cows love composting barns at calving time. I recall one barn where, at calving time, the farm worker said to me that it was like working on a hobby farm.

Another farmer said to me that he had to reduce the work schedules because it took all the stress out of calving and the work hours were much less.

The value of compost as fertiliser also needs to be considered. There can be considerable savings, particularly in nitrogen, but also other elements.

Agri expert: Keith Woodford

The first thing to work out in relation to designing the barn itself is the cow stocking rate. Will the cows be in the barn 24/7 during winter or will they still be going out for say three or four hours of grazing except during exceptionally bad weather? Under what conditions will the cows use the barn at other times of the year? These are the questions that will determine the area of bedding per cow.

Not all composting barns are successful. There are multiple reasons for this, starting with flawed design.

My estimate is that less than half the existing barns are working at an acceptable level. This is a big issue as a composting barn is a major investment.

When composting is working well then it all looks so easy. However, when things start to go wrong, then it is easy to miss the early warning signs.

The efficiency of moisture removal from the urine and dung deposited in the bedding is critical. Particularly in the South Island, I am impressed by the benefits of roll-up side curtains as a management tool to get

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I am particularly keen on Giant Miscanthus for bedding. This is a sterile pant that has to be reproduced vegetatively, and this can be somewhat of a hassle.

However, I am convinced that Giant Miscanthus is going to become a key component of composting systems in New Zealand, with farmers typically growing their own Miscanthus, often on land that has low value.

Giant Miscanthus has been in New Zealand for more than ten years but it is only now that the growing and harvesting technologies are starting to be applied properly. Also, currently we only have one variety of Miscanthus available, and almost certainly this is not the best variety in many parts of New Zealand. Plans to get new varieties into New Zealand are under way.

Regardless of the specific type of bedding that is used, there is a very similar heating value when measured per tonne of dry matter. However, the heating value per cubic metre depends very much on the bulk density of the material. There is no value in paying for air.

If purchasing bedding per tonne, then knowledge of dry matter content is also essential. Woodchip and sawdust from freshly harvested timber can be 50% water, and one does not want to pay for this. Also, much of the heating value inherent in the bedding material can be used up in getting rid of this initial water.

One of the advantages of Miscanthus is that the dry matter, when correctly harvested at the correct time, is likely to be over 85% and perhaps close to 90%.

Accordingly, it heats up very quickly.

the chimney effect operating effectively. In the South Island I would never consider building a barn without these curtains.

Bedding can be sawdust, wood shavings, woodchip or any other vegetative material that is high in lignin.

Any plant that stands 2 metres or more in height is going to be high in lignin. Conversely, wheat and other short stemmed cereals will be low in lignin and the straw turn to mush rather than sweet-smelling compost.

Ideally, the temperature in the compost should be above 50 degrees C and the moisture level preferably no more than about 65%. Seventy percent is the moisture irrecoverable level at which problems quickly multiply.

One of the problems with composting-barn developments in New Zealand is that the formal R&D organisations have been very slow to come to the party.

Hence, most of the knowledge acquisition has been led by farmers working by trial and error and then sharing their knowledge.

One of the challenges we have been seeing in some North Island situations, where the barn is used for lactating cows, is for E coli mastitis to become a major issue. There will be solutions to prevent E coli from becoming a limiting factor, but we are not quite there yet. What we do know is a high level of discipline is needed to ensure the compost stays above 50 degrees C for prolonged periods and ensuring the fermentation is always aerobic. E coli loves the cooler non-aerobic compost sometimes found at depth in the compost.

Growing miscanthus can offer further benefits

For more information or to discuss your specific needs, please contact us on: 0800 686 119

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Solar Panels on Cow Barns: Is SelfSufficient Energy Possible on NZ Dairy Farms?

As the world grapples with climate change and rising energy costs, New Zealand's dairy industry faces a unique opportunity. What if our dairy farms could generate their own electricity, right from the rooftops of their cow barns? It's an idea that's beginning to take off overseas and could soon make waves here in New Zealand.

Learning from Overseas A progressive dairy farmer in southern Pennsylvania, USA, provides an inspiring example. Eric Weaver, from the 10th Generation Dairyman YouTube channel, recently installed 324 solar panels on the south side of his barn roof, creating a 175-kilowatt system. Featuring 550-watt panels, the setup aims to power the entire farm and even produce a surplus.

Initially sceptical, Eric was impressed by the financial viability of the project. "I thought solar was something that only worked if subsidised by the government," he said. However, after accounting for tax credits and rebates, he found that the panels would pay for themselves within four years. Even during the short, sun-deprived days of winter, the panels performed admirably, hinting at the potential for year-round energy generation.

Harnessing the Sun: Eric Weaver's Pennsylvania dairy barn, equipped with 324 solar panels, generates 175 kilowatts of power.

The system has produced the expected amount of electricity through the first two months, despite it being winter. Eric is optimistic about the panels' performance in the sunnier months of May, June, and July. "It's great to have these panels producing all the electricity we need, especially during the summer when we run the fans," he noted.

Local Efforts and Hurdles While the American example is promising, how feasible is this for New Zealand dairy farms? Currently, there are no widely known instances of Kiwi barns sporting solar panels.

However, local companies are exploring renewable energy solutions for the agricultural sector.

Peter Saunders from Solagri, a Canterbury based energy company, highlights the potential benefits. "Dairy is a big market with a large and predictable load profile. While there are timing issues with when they milk, in comparison to when the solar panels are making power, there are plenty of things that can be time-shifted to better use the solar energy, such as effluent pumps," Saunders explains.

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Crunching the Numbers In the US, financial incentives were crucial. Tax credits and power company rebates significantly reduced the payback period. For New Zealand farmers, a similar approach could unlock the potential of solar power.

Collaboration between the government and industry bodies to create attractive financial packages could spur a surge in solar energy projects on farms.

Peter Saunders notes that industry conditions are also in favour of solar power becoming a major feature on NZ dairy farms. "The ongoing increase in demand for electricity and limited generation growth in the short term are likely to continue pushing electricity prices up.

This will make solar look like a more attractive option, particularly given the downward price pressure of panels at the moment."

Beyond financial savings, the benefits are clear.

Generating their own electricity allows farmers to achieve energy independence, shielding themselves from volatile power prices. Additionally, reducing carbon footprints aligns with global sustainability goals, enhancing the green credentials of our dairy industry.

The Road Ahead Imagine New Zealand barns glistening with solar panels, harnessing the power of our abundant sunshine. It's a vision that could revolutionize our farming landscape, making energy independence a reality.

While the journey towards self-sufficient energy on New Zealand dairy farms is just beginning, the potential is enormous. With overseas success stories and growing local interest, it's an exciting time for innovation in our agricultural sector.

Eric Weaver 10th Generation Dairyman

"There is also the whole irrigation part of the dairy electricity use profile."

The question now is whether New Zealand farmers are ready to embrace this solar revolution. It will take a willingness to innovate, invest, and envision a future where our farms are not just producers of milk, but also generators of clean, renewable energy. The opportunity is there – it's up to us to seize it.

Solagri has installed solar panels at five New Zealand dairy farms, with a further two installations underway.

These efforts demonstrate the adaptability of solar energy in agriculture, suggesting it's not a question of if, but when, we'll see wider adoption in New Zealand.

However, there are unique challenges here in Aotearoa.

Factors like our distinct environmental conditions, regulatory landscape, and upfront investment costs need careful consideration. Roof orientation and sunlight availability are crucial for maximizing efficiency.

Moreover, farmers will need support from government incentives to make the financials stack up. Saunders also points out a practical hurdle: "Finding experienced professional installers is a significant challenge."

Solagri Energy CEO Peter Saunders with business partner Hamish Hutton.

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New Feed / Wintering Pad Surface with Flood Wash for Jersey Girl Jersey Girl Farm, located near Winton, recently upgraded its infrastructure by installing a new feed pad surface with a flood wash system. This initiative aimed to improve the operational efficiency on the farm and lift cow comfort. NumatAGRI recently visited the farm to find out how the new system is performing.

Project Scope and Objectives The primary objective of the project was to create a system that ensured cow comfort by providing a dry and clean environment while also being practical and user-friendly for the farmers.

Key Components and Features of the System Conversion Bart Geypen, the Construction Manager, explained, "This setup has a calculated gradient. Each barn is 26 meters wide and gets flushed with 60,000 litres of greenwash water in under five minutes."

• Siesta Rubber Bedding: Used for the wintering setup, providing a softer and more comfortable surface for cows to lay on continuously.

• Sloped Gradient: Each barn,measuring 26 meters wide,was designed with a slope to facilitate the flood wash system.

Cows enjoy the New Feed / Wintering Pad: 24h / 7days a week from May right through June and July.

• Greenwash Water System: Utilizes 60,000 litres of water to clean each barn in under five minutes.

• Flood Wash System: Includes two interconnected storage tanks of 30,000 litres each. The tanks release water through a main pipe with risers every 300mm, creating a wave that cleans the area.

• Effluent Management: Captured at the end of the barns, the effluent is stored in a 160,000-liter sump and pumped back to the main effluent setup for reuse.

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Outcomes and Performance

Advice for Other Farmers

The new system has significantly improved cow comfort, keeping them dry and clean. The farm now uses the flood wash system three times a day, saving approximately five hours of labour daily compared to the previous year.

Bart emphasized the financial benefits, stating, "The combination of savings in mulch, labour, and tractor running costs gives this setup a much greater ROI."

Bart advises other farmers to consider the ROI, factoring in labour, tractor, mulch, and feed savings. He emphasizes the importance of maintaining the greenwash system efficiently and performing flood washes at least once a day to avoid build-up. "Doing a ROI considering labour, tractor, mulch, feed saved, etc., might show how affordable it really is," he recommended.

Feedback from Jersey Girl Farm Team The feedback has been overwhelmingly positive. The team reports that the cows are comfortable, dry, and clean, and the flood wash system is simple enough to allow staff to handle daily tasks efficiently. "The initial feedback has been amazing," Bart shared. "Cows are comfy, dry, and clean. It’s saving them five hours of labour a day compared to last year in the composting barn."

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Customer Case Study: Borries' Feed Pad in Waitaki

The Borrie’s Dairy Farm, owned by the dedicated and innovative duo Michelle and Rogan Borrie, is one of the three dairy farms they manage in the Lower Waitaki Plains.

Their operation features an expansive milking operation with approximately 2,500 cows during winter. Recognizing the need for change and the impact of weather on their farming practices, they decided to undertake an ambitious project – the construction of a new feed pad on their 500-cow dairy farm.

The cows spend 24h / 7days a week starting in May through June and July on the feed / wintering pad.

Identifying a Need “Obviously things move forward and for environmental reasons we decided to put a feed pad on this 500-cow dairy farm,” Michelle noted, emphasizing their commitment to both animal welfare and environmental sustainability.

Their decision was precipitated by challenging winters characterized by heavy rainfall that turned the farm into a muddy mess, causing difficulty in managing cows and pasture.

In pursuit of a more effective and efficient system, the couple toured several farms to study existing feed pad designs.

Designing the Feed Pad From their explorative tours, the Borries identified features they liked and aspects they wished to avoid in their own design. “We saw ones we liked, but a lot of them had woodchips where we think woodchips are getting harder to get and dearer,” said Rogan, explaining their decision to opt for a rubber matting option instead. The rubber matting had a higher upfront cost but promised longevity and costeffectiveness in the long run.

The Role of NumatAGRI Construction Their project was taken on by NumatAGRI’s construction division. “After talking to them, they were very keen to come on board and were very enthusiastic and wanted to come and build it for us. So, we thought, well, why not? And we’re very happy with the results,” Michelle added. NumatAGRI’s willingness to participate and dedication to the project was a driving force behind the successful implementation of the feed pad.

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Using the Feed Pad

Reflection and Future Plans

The newly constructed feed pad has been a gamechanger. Cows are fed 3 to 4 kilograms of maize and grass silage on the feed pad and then guided to the milking shed. Rogan valued simplicity in the design to avoid potential breakdowns. “There’s a scraper for the tractor and motorbike and a wheel pusher to push the silage in. The sharemilker’s got a silage wagon to feed the silage out. So, there’s no mixer wagons. There’s nothing really to break down,” Rogan explained. They plan to keep the cows on the feed pad 24/7 during winter, feeding them maize and grass silage.

Michelle appreciated the smooth working relationship they had with NumatAGRI, as the project execution was seamless with no unexpected hurdles. “I’ve worked with a lot of building agencies and stuff with lots of things happening on farm constantly. With NumatAgri, this was just very smooth,” she commented. The couple is waiting to evaluate the full effectiveness of the feed pad design through a complete winter cycle. If it proves successful, they plan to replicate the design on their other two dairy farms, accommodating 600 and 1,100 cows respectively.

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Open Day Highlights at Borries' Feed Pad.

The Borries' Feed Pad Open Day provided valuable insights into the farm's new feed pad surface. Rogan, from the Borries' farm team, shared their journey and the benefits they've seen since implementation.

The farm, which grazes 485 cows and winters just over 500, faced challenges with their previous setup due to harsh weather conditions. This led to uncomfortable, wet conditions for the cows. The new feed pad surface has significantly improved cow comfort. Within a week, the cows adapted, finding their favourite spots on the mats.

Operational Benefits:

Technical Aspects:

• Enhanced monitoring of cows, especially those close to calving.

• Siesta mats provide a soft, comfortable surface.

• Simple cleaning process saves significant labour time.

• Daily routine involves pushing leftover feed to the concrete nib wall and feeding out, improving efficiency.

• Optimal drainage slope keeps the area clean and dry.

• Cleaning with water maintains hygiene.

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Feedback has been overwhelmingly positive.

The new system has not only improved cow comfort but also operational efficiency, reducing labour and enhancing overall farm management. Rogan emphasized the system's simplicity, allowing staff to manage daily tasks effectively.

The event concluded with a Q&A session, highlighting the successful implementation of the new feed pad surface at Borries' farm. The Open Day offered practical advice for dairy farmers facing similar challenges.

Check out the full case study with video interview:

numatagri.co.nz/case-studies/borries

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Revolutionizing Dairy Barn Design: An Interview with Greg McCalman from Entegra In an engaging conversation, Greg McCalman from Entegra shared the story behind the innovative Ridgeback barn design, a structure that could be a game-changer for New Zealand dairy farmers seeking to house cows in barns.

Harnessing Natural Airflow The Birth of Ridgeback Barns The Ridgeback barn design began as a solution to a unique challenge faced by one of Entegra's clients. The farm needed a wide barn, but local regulations imposed a height restriction. Traditional roof pitches would have made the barn far too tall, and using multiple gables to reduce height wouldn't provide adequate ventilation. So, Greg and his team sought an unconventional solution.

"We were dealing with a height restriction of 15 meters for a wide barn," Greg explains. "A traditional 18 to 22-degree roof pitch would have made the barn about 25 meters high. We considered using three gables, but that wouldn't ventilate properly. So, we had to get creative."

To solve this, they turned to the field of aviation for ideas. "We thought about airflow and how air moves around an airplane wing," Greg continues. "This led us to design a barn that promotes efficient ventilation without exceeding height limits."

A standout feature of the Ridgeback barn is its ability to harness natural airflow, maintaining a comfortable environment for dairy cows. Greg elaborates on the design’s ability to harness natural airflow: "The roof shape creates a chimney effect, where hot air rises quickly, drawing in cooler air from the sides. This natural airflow significantly reduces heat stress on cows, making the barn feel almost air-conditioned, even on the hottest days."

The Ridgeback barn excels in promoting airflow, essential for cow comfort and health. Traditional barns often fail to provide adequate ventilation, especially during still, hot weather. The Ridgeback's unique curved roof ensures continuous airflow, enhancing the barn's cooling efficiency by 20% more than traditional gable roofs.

Adapting to Cooler, Wetter Climates One of the critical advantages of the Ridgeback barn design is its suitability for cooler, wetter climates, which are common in some parts of New Zealand. "In places with high humidity and frequent rainfall, maintaining a dry and comfortable environment for cows is crucial. The Ridgeback barn's design facilitates excellent ventilation, helping to keep the interior dry and reducing issues related to damp conditions," Greg explains.

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Benefits for Dairy Farmers

Practical Insights for Farmers

For dairy farmers, the benefits of the Ridgeback barn are clear. The improved airflow reduces heat stress, crucial for maintaining milk production during hot weather.

Additionally, the design helps control environmental factors that can lead to mastitis, promoting better overall health and productivity in dairy cows.

Greg emphasizes the importance of understanding each farm's unique needs. "The biggest challenge is identifying the primary goals for the barn. Whether it's keeping cows on farm over winter, or lifting overall milk production, or pre-empting future regulation, each farm has specific requirements.”

The Bottom Line Entegra's Ridgeback barn design offers an innovative solution for dairy farmers looking to enhance cow comfort and productivity. By drawing inspiration from aviation, Greg McCalman and his team have created a structure that provides 20% better airflow than traditional gable roofs, which is beneficial for cow health and composting systems.

For more information and detailed case studies, visit NumatAGRI's website to explore how the Ridgeback barn can transform your dairy farming practices. numatagri.co.nz/construction

Chat to a construction consultant today.

Call 0800 686 119 numatagri.co.nz/construction/