Building for the cow - English edition

With a degree in veterinary science and a strong interest in animal practice before refocusing on helping farmers sharpen their

Comfortable cows stay healthy and productive. The same is true for people,

critical thinking and observation skills, and increasing their awareness

when they are able to work in a pleasant and uplifting environment.

of the needs of their livestock and other management issues.

Barn design is a process in which several perspectives must be taken into consideration as the project takes shape. These perspectives include the

With his company Vetvice, Jan developed the Cow Signals® concept

needs of the cow, labor efficiency and keeping capital

and wrote the successful series of Cow Signal books. Vetvice is active

costs in check, . It is also important to ensure the barn

in more than 30 countries, providing lectures and training sessions in

design is flexible so it can cope with expansion projects

the areas of Cow Signals, hoof care, fertility and reproduction,

in the future.

management of calves and heifers, dry period and transition

A good barn provides the platform for a successful

management, and building for the cow.

dairy, and no dairy farmer builds often enough to

The book series Future Farming® goes beyond the needs of the cow,

good facility on their own. You should seek the advice

and focuses on the management of livestock, and people and other

of others from a variety of fields of expertise and

Jack Rodenburg, a thirty year veteran in dairy facilities design and

The basic design must be right, as it is virtually impossible to change at a

management in Canada have enhanced the Vetvice team and this

later stage and it is a determining factor in the health and productivity of the

practical guide.

cows in the barn. But the details must be correct as well. If a gate does not swing the right way, or two people are needed to catch and restrain a cow

“An excellent book with many illustrations and compact, clearly written

after all, then you have missed an opportunity to save labor. Building for

text. It provides outstanding information that you can use immediately.”

the cow presents you with knowledge, insight and guidelines to help you develop an excellent barn design. Ideas are presented in clear language, with many pictures, sketches and practical tips.

The advisors and trainers of Vetvice and DairyLogix; this book was based in part on their expertise, knowledge and creativity.

From left to right: Standing: Nico Vreeburg (veterinarian/trainer, barn construction, dairy farm management) Joep Driessen (veterinarian/trainer, Cow Signals Company) Bertjan Westerlaan (veterinarian/trainer, barn construction, dairy farm management) Marcel Drint (veterinarian/trainer, hoof health) Sitting: Jan Hulsen (veterinarian/trainer, large dairy management) Jack Rodenburg (dairy design specialist, DairyLogix)

Building for the cow

www.vetvice.com

www.dairylogix.com

seven key words, which form the corners of the cow signals diamond. These seven basic needs are feed, water, light, air, rest and space, and health.

As a dairy farmer you should always pay close attention to these needs, in order to ensure good health and welfare and optimum milk production. Building for the cow also demands special attention to the corners of the cow signals diamond.

“A barn plan that does not get ripped up at least twice is probably not a good design.”

www.roodbont.com

The basic needs of the cow can be summarized by

Jan Hulsen Jack Rodenburg

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Health

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Light

experience, because such advice is essential.

Jack Rodenburg

resources on the modern dairy farm. The insights of co-author

Jan Hulsen

have sufficient experience in designing and building a

Building for the cow

communication he enjoyed three years of on farm work in a large

The cows and the workers should be the priorities in barn design.

The Cow Signals Diamond

Space

Jan Hulsen grew up on a farm with dairy cattle and finishing pigs.

“Saving 10 minutes of labor every day will save you one and a half weeks of labor each year. With healthy cows and smart work routines you can save even more”

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About the authors

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Colophon

Future Farming Building for the cow

For books and special editions:

Authors Jan Hulsen, Vetvice® Jack Rodenburg, DairyLogix

Roodbont Publishers Postbus 4103

Photographs Jan Hulsen (unless stated otherwise)

NL-7200 BC Zutphen T (0575) 54 56 88 F (0575) 54 69 90

Graphics Herman Roozen

www.roodbont.com info@roodbont.com

Design Erik de Bruin, Varwig Design

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With the collaboration of Nico Vreeburg Bertjan Westerlaan Joep Driessen

For lectures, training and consultancy worldwide:

Vetvice® Group

Moerstraatsebaan 115

And thanks to: Neil Anderson, Nigel Cook, Marcel Drint, Paul Hulsen, Anne Kloek, Herbert Meulemans, Wiebe Veenstra, Thijs Neutel and the numerous staff members of dairies and institutions that toil in the business of dairy production and design and construction of dairy facilities. Also a special thanks to all the dairy farmers who were willing to share their knowledge and experiences with the authors and who welcomed us to their farms for discussion and photographs.

NL-4614 PC Bergen op Zoom T (0165) 30 43 05 F (0165) 30 37 58 www.vetvice.com

www.cowsignals.com info@vetvice.com

For books, lectures and training in Canada:

Jack Rodenburg

DairyLogix Consulting

Telephone: 519-467-5294 Fax: 519-467-5845

814471 Muir Line, RR# 4, Woodstock, Ontario, Canada, N4S 7V8 www.dairylogix.com © Jan Hulsen, 2010

jack@dairylogix.com

No part of this book may be duplicated, photocopied, reprinted or reproduced

Building for the cow is part of the Future Farming® book series.

in any way without prior written permission from the publisher.

Future Farming® is a registered trade mark of Vetvice.

The authors and publishers have made every effort to ensure the accuracy and completeness of information contained in this book. , The authors and publish-

ISBN: 978-90-8740-020-0

ers do not accept any liability due to damage of any kind resulting from actions and/or decisions based on this information.

2

Building for the cow

content

Introduction

1 The four cornerstones of barn design Build a system, not just a barn The cow: comfort, health and productivity

4

6 6 8

The labor: efficiency, productivity and quality

10

The future: expandable and flexible

12

The cost: build simple, robust and inexpensive

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2 Building for the cow

16 16

Measurements of the cow

18

The needs of the cow: the Cow Signals diamond

19

Feed

20

Water

22

Space

24

Air

27

Light

30

Rest

32

Health

35

Standing up and lying down

38

Unos and unusual behavior of cows and people

40

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From the cow’s perspective

Appendix: Inspiration layout sketches

Content

Milking barn with parlor

42

Robotic milking barn

44

Transition barn

45

Heifer barn

46

Index

47

3

Introduction

Building for the cow

A good barn is designed to meet the needs of the cow, so that the animals stay healthy and productive. The layout should also ensure that the work can be done efficiently, and it should provide a pleasant working environment.

The future development of the farmstead should never be ignored in barn design, because almost every farm business is likely to expand again in five to ten years.

This book will focus on the four cornerstones of barn design with the emphasis on the needs of the cow, as sound investments in cow comfort, and a reduced workload, will be repaid every day that the barn is used.

Well-being= housing + animal care

To make good decisions you need a clear vision of your management plan that can be translated into concrete objectives. This clarifies the aims you want to accomplish and makes the choices to be made much clearer. Having clear objectives also makes it possible to use advisors effectively.

Knowing yourself and understanding how you make decisions is essential in making the right choices about barn design. For example, some people are perfectionists by nature and work out every detail well in advance, while others are more task oriented and work things out as they go. Some people want to spend as little as possible, while others seek maximum security.

Some choices will be the same for everyone. For example, the dairyman who wants the best for his cows and for himself will choose a two row layout. This layout is also best for farmers who are less focused on husbandry and who spend less time in the barn.

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A barn can only perform as well as the management of the stockmen caring for the animals it houses. Good cow managers can create good cow comfort and well-being in less than ideal barns, but poor cow managers can turn an ideal barn into a nightmare for the animals. There is no magic bullet, no wonder drug, or cure-all that prevents or solves all the problems that can and will happen in a dairy barn.

Build a facility that suits you

Focused on the animals

Limited herd size, simple, extensive, pasture, hardy breed.

Intensive, high production, deals effectively with complex information, materials and systems Pitfall: organization of tasks and efficiency

Easy going

Extensive, Simple and Robust Low Cost. Dual Purpose Breed Coworker/family member who performs the animal care focused tasks

Perfectionist Single operator: fairly intensive, robust, good advisors (nutrition, health).

Multiple operators: animal focus provided by coworkers, reasonably to very intensive, mechanized and organized

Focused on the task

Choose a farming system that suits your management style.

Can you advise me?

Of course, about what?

About making more money. I am a business owner.

Make money of course. Can you advise me?

And what does your business do?

Don’t hire advisors, they have nothing to offer.

Good tip. I already suspected hiring advisors would not be worthwhile.

The correct interpretation is that hiring advisors is not worthwhile for you.

If you don’t have specific goals and objectives, no one can advise you.

4

Building for the cow

Introduction

Tips from the contributors to this book: Nico Vreeburg, veterinarian, consultant barn design, health management of dairy cattle

Joep Driessen, veterinarian and international Cow Signals® trainer communication ‘A cow never lies! Look at and listen to the cow and her body language, and you will know what to do to make her happy.

She will gratefully pay you back with better health and with milk in the tank...’

Bertjan Westerlaan, veterinarian , consultant barn design, health management of dairy cattle

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Jan Hulsen, veterinarian, consultant dairy health and management, business strategy and organization.

‘Caring for one sick cow is as time consuming as caring for 40 healthy ones. So invest in facilities where the healthy cow stays healthy. Only then can we care for more animals per person in a cow friendly manner. A healthy herd makes for an enjoyable job as well as putting money in your pocket. It also leaves the farmer with more time for his family and social life.’

‘If you understand it, you will also see it (Johan Cruijff).’ ‘The best dairies are run by managers with a good understanding of how cows and people function. They are interested people, who can transform a vision into concrete choices, and stick to them. They understand how management processes work; they understand the success factors and are aware of the risks.

‘As an advisor you base your advice on reliable information.

With consideration for the goals, possibilities and character of the farmer, you use your creativity and practical experience to provide recommendations.

These recommendations are often very specific and unique to the situation.’

Jack Rodenburg, dairy specialist, barn design consultant, modern dairy management.

‘As we automate milking, feeding and manure handling, taking care of special needs and treating sick cows will become the major labor factors in the dairy of the future. “Building for the cow”, so she stays healthy and designing good facilities for handling, calving, transition and other special needs, will make the difference between outstanding farms and the rest.’

Introduction

5

The four cornerstones of barn design

CHAPTER 1

The four cornerstones of barn design

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An ideal barn design meets a variety of requirements. It addresses the comfort and health needs of the cows and replacements, and the needs of the employees for a practical and healthy work environment. The structure must comply with environmental regulations and integrate well in the landscape. And it must generate a sufficient return on investment. But what are the most important factors and where do you begin? The animals and the people must come first. Then regulatory requirements, followed by financial considerations, which greatly depend on the daily performance of the cows and people in the barn.

Build a system, not just a barn

You are not building just a barn, you are building a farmstead and a management system, so your drawing is a component of a management plan. The barn should reflect the needs of the cow and the way you plan to work in it (working and walking routes).

The management plan also includes a farmstead plan that shows the location of the barn relative to other structures and their function. Where is the feed stored? How will feed be moved from storage to the cows? Where is the manure stored, and how is it brought there? Where are the calves housed, and heifers and dry cows? How are these animals moved?

Very likely there will be employees. Where do they change clothes? Where do they take breaks? Are there washroom and shower facilities? How do you keep these areas clean and warm? Also consider people who are not on the payroll, such as the hoof trimmer and the veterinarian. How do visitors approach and enter your facilities to deliver feed or materials? And to remove milk, livestock or manure? Are they happy to come to your farm, or is it a difficult and dirty experience? Where can you sit down with advisors and sales people? A well designed facility also relates well to its surroundings. It will look well cared for, with safe and convenient traffic access with a wide entrance and good sight lines.

A dairy enterprise should strive to make optimal use of the three most important production factors: the cows, the employees, and the invested money. Along with this it needs to ensure long term sustainability (expansion, environment, social acceptance).

The work of the owner/manager varies with Dairy farms go through growth and development stages that each require their own management style. This does not mean every farm will go through each stage or that every farm develops to stage 4: Bottleneck:

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1. Small number of cows, you do all the work yourself.

You multi-task, for example you monitor feeding while you feed and milking while you milk. You do the work walking and want things close together with good oversight.

The small herd means tasks like insemination and calving are infrequent. There is little automation or mechanization.

Big differences with larger herds.

Building for the cow

The four cornerstones of barn design

The four cornerstones of barn design

2

1

1.

2.

3.

4.

4

cow comfort 3 labor efficiency flexible and expandable low cost, structurally sound, simple

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These four themes or cornerstones provide good guidelines for developing a functional dairy barn. They have to be applied within the framework of regulatory compliance with environmental and landscape requirements.

A good business strategy is based on the strengths and weaknesses and the personal choices of the dairy entrepreneur.

How do you see yourself? And are you that person, or is it who you want to be and can become?

the herd size.

2. Higher cow numbers, greater dependence on custom operators.

You still do the dairy work yourself, you know your cows, and do your planning mentally. You organize the work according to your personal plans and daily schedule. You are always busy and you struggle to work efficiently. Some automation and mechanization is used. .

Not much time to think.

3. Working with full time employees.

You need help with daily chores, and while you still work on the farm you have to manage people and processes as well as cows.

Formal planning and work organization.

Too small for a stage production, but too big for a one man show.

Chapter 1 The four cornerstones of barn design

4. Working with so many employees that there is a clear management role.

The size of the operation makes it possible to define specific measurable tasks that can be organized independently. You are the investor, entrepreneur, manager and farmer.

Management, entrepreneurship and good employees.

7

The cow: comfort, health and productivity

Cow comfort – The cow comes first

Management question You have expanded the herd and it will take more time for feeding and feed handling, moving cattle and hauling manure, unless you invest in larger equipment.

How do you tackle this?

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Cow comfort is the foundation for high milk production, good fertility, minimal problems and happy employees. But comfort and health are complex issues to organize. They depend on numerous factors and require excellent monitoring so you know how to respond when something goes wrong.

Happy and healthy cows are the result of an excellent barn or pasture, as well as first-rate management within that environment.

Of course there has to be room on the farmstead and in the buildings for larger tractors and wagons and for example for bulk storage in totes.

Comfort and health form the basis for milk production, fertility, labor efficiency and enjoyment of the job.

The Cow Signals Diamond d

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Light

Space

e Fe

Health

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The basic needs of the cow can be summarized by seven key words, which form the corners of the cow signals diamond. These seven basic needs are feed, water, light, air, rest and space, and health.

Health is the result of the other six points, and it is also a basic need itself. Freedom from infections, injuries and metabolic problems also exists as a separate attribute among the needs of the cow. See chapter 2.

8

Draw up a farmstead plan that addresses the expansion of feed storage, manure storage, materials storage, calf, heifer and dry cow housing. If you double the number of milking cows, space for replacements, dry cows, special needs, and feed and manure storage also doubles.

The farmstead plan also visualizes the traffic patterns (what material is transported from where to where, how and how often). And it examines transport of materials on and off the farmstead. You need to include a clean route (for traffic originating on the farm) and a contaminated route (for all traffic originating off the farm). You should also consider drainage, security (who enters your farmstead?), and safety (children, collisions, sight lines, lighting, turning room, entrance/exit)

To realize economies of scale, the bigger dairy should be able to deal with bulk feed and supplies, so it must allow access to large trucks and trailers.

Building for the cow

The cow: comfort, health and productivity

Focus on cows and cow care

The barn should offer comfortable housing to all groups of animals and it should facilitate timely, effective and efficient handling, with minimal stress for both the animals and the handlers.

Health and well-being are largely the result of the quality of management. A well designed barn makes it very easy for the farmer to apply the most desirable management at the most ideal time.

With regard to animal health, preventative handling, such as vaccination, hoof care, and management at dry off are very important. This means that you should apply a strict day, week and annual work routine. The barn design should make the work easy to do so it encourages everyone to deliver top effort and results.

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100 milking cows: what should you expect?

A hoof check involves picking up the feet of the cow and examining them. If required this includes trimming to improve the shape, and to correct deformities. Infections (strawberry foot, foot rot) should be treated. You should do a hoof check two to three times per year for every cow in the herd.

Typical distribution of the dairy herd • 100 milking cows • 11 dry cows • 3 fresh heifers • 2 sick cows (0 to 4) • 4 fresh cows (0-14 days)

These are average numbers based on a 25% replacement rate, an eight week dry period, and a 400 day calving interval. Plan adequate space for special needs cows. The actual numbers depend on management choices (e.g. length of dry period), health problems, calving interval, replacement rate and other variables.

Weekly events • 2 calvings • 1.5 cows to dry off • 0.5 new heifers coming in from the heifer barn • 4 inseminations • 4 hoof checks (60 days, at dry off and at introduction) • 3-6 reproductive/pregnancy exams • 1 mastitis case These numbers provide an overview of the services, time, expertise, and people needed to carry out the handling requirements effectively, at a time that you determine.

Chapter 1 The four cornerstones of barn design

On the left, a bedded pack, which can be used for weak and sick cows and cows in heat. In the work room behind the handling chute there is a refrigerator, a sink, a computer and all materials needed for handling and insemination.

Management question

How do you ensure that each employee always knows how specific tasks are to be completed and how other workers will have done them previously?

ith are done w “When you rd co re w, co d the calf an the calving the birth in n the tools record. Clea e them or st d an ed us ect place. in the corr e ials that ar Refill mater and note ed sh ni fi nearly rchases on required pu board.” te hi w the

Standard operating procedures (SOPs or protocols) ensure that everyone completes tasks in the same way, so that the likelihood of first time success is maximized and work is completed efficiently.

Furthermore SOPs make it easy to benchmark success and adapt procedures when necessary.

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The labor: efficienc y, produc tivit y and qualit y

Building blocks for labor efficiency

Labor efficiency can be organized via a number of basic principles. If you think in terms of orderly processes, this becomes logical. Look out for places where animals, feed, manure and machinery cross paths, since these places are often bottlenecks.

1. Avoid surprises and problems

A clock in the barn is an asset if you are work according to a schedule or protocol.

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You want to perform as well as possible using minimum resources. And you don’t want unexpected extras such as a sick cow. Along with cow comfort this will depend on the management and manner in which you do the work.

This involves: - a strict day, week, month and year work plan; - all tasks completed properly the first time; - taking care that cows stay healthy.

Work planning should put production and prevention first and should include all activities, even things like scheduled discussions with advisors and sales people. Working with SOPs is an absolute requirement to making good use of an efficient barn layout and to ensure that all tasks are done correctly the first time.

2. Straight lines through the barn

Large doors in the gable ends, and straight lines through the length of the barn make tasks like feeding, bedding and manure removal easier and ensure that these things can be mechanized.

A dead end feed alley means you have to remove manure via the feed alley. Feeding, observation and manure removal are all inconvenient. These activities are done badly , or the pens don’t get used as in this photo.

3. Mechanization

The feed processing center of an automatic feeding system.

For dairies of a certain scale, machines work faster and cheaper. And often they deliver better results with fewer mistakes.

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Don’t just mechanize work, feed and manure, but also information management. For example, pocket computers and attention lists. Connected to a weather station, these controls open and close the sidewall curtains.

Building for the cow

The labor: efficienc y, produc tivit y and qualit y

4. Combining common handling activities In time

You can create a work center if your special needs group, handling chute, management rail and calving area are close together and beside a vet. room. This groups the cows that require frequent monitoring. You can also do this by grouping the herd, for example, a fresh cow group, a breeding age heifer group, a dry off cow group and a pregnant group. And with special post milking separation areas.

Here a fresh cow is being drenched in the milking parlor, which is not a good place for handling.

An automatic selection gate. This gate recognizes the cow from the transponder on her neck strap and opens the gate for cows to be sorted. In this way all attention cows can be collected in the sort pen, and subsequently they can be dealt with in a single work session, efficiently and safely by a professional in a chute or management rail.

5. Specializing

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In specific places

Rule # 1

One person should be able to fetch and restrain one cow for handling in less than one minute, and in one correct action, give the appropriate treatment.

Employees with more experience and knowledge work quicker and deliver better results with fewer errors and less need for repeat treatment. This herd manager monitors the fresh cows and applies treatment as needed. By bringing together similar tasks in a well organized handling area you can also reduce the cost of using outside professionals such as hoof trimmers and veterinarians.

Management question You want to work efficiently. How will you achieve this?

Especially in relation to labor efficiency, barn design, barn layout, location of treatment tools, and organization of handling must be perfected to the smallest detail. Achieve this through good planning including a detailed facilities layout and work plan.

When writing a work plan consider all the tasks that are conducted in the barn. Think about how you will complete these tasks and consider all pathways for people, cows, materials, information and manure.

One person must be able to do the work alone, including handling all cows. Gates

Chapter 1 The four cornerstones of barn design

should latch easily and should be designed to be opened with one hand. Also think about good lighting, placement of electrical outlets, warm water, tool storage, maintenance, cleaning equipment, waste, wind, rain and cold drafts‌.

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The future: expandable and flexible

Management question

Build for future expansion and development

To be sustainable and successful over the long term, all businesses need to grow and change over time. Even if you have a specific strategy to milk no more cows, the facilities and the site should be flexible. Because you never know.

Expansion proceeds in stages with specific steps. These steps are related to the business strategy and are almost identical for dairies using similar systems. The common aspects originate in the management philosophy and in the facilities themselves.

Because you need to be flexible in every aspect, you need to think big as in spacious and flexible, in software, in work organization and execution, in machines, in cow traffic, in ventilation, etc. Technology and knowledge will continue to develop.

Important considerations for expansion include: - locate mixing points on manure pits where they will not be extended; - placement of manure drops from alley scrapers (at the end or in the center); - feed delivery and mangers (straight lines).

- in slatted floor barns robotic scrapers clean crossovers as well as alleys and are more adaptable than alley scrapers when the barn is expanded. If raceway manure channels run perpendicular to the length of the barn, pump out locations beside the barn will not interfere with making the barn longer.

A separation area along the return lane from the milking parlor, which is as wide as the parlor is long. Can this be done better? Is this expandable?

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Manure is removed via the manger. This is awkward and contaminates feed. With expansion this pen will be too small, and it cannot be made bigger.

Without a holding area, a dairy cannot easily expand. A holding area also ensures cows enter the parlor more quickly.

Here the fresh cows in the bedded pack go into the parlor as the first group to be milked.

Water

Feeding/resting area group 1

B

C

Feed alley

Feeding/resting area group 2

Water

Calving/ fresh cows/ lame cows

Water

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Parlor

A

Water

If you think ahead you can build in practical phases. This lowers the building costs. This barn has a manure pit with uniform raceway widths with slats and solid panels. You milk the fresh and lame cows first, then group 1 and then group 2. The area at A is used as holding area. Post milking separation is possible at C. Group 1 can access the freestalls behind the crowd gate. With the first expansion, you lengthen the barn, and create a new crossover at B. Remove some freestalls so A becomes a bigger holding area and use these stalls in the new addition. The right half of group 2 becomes an area for fresh cows, dry cows and close-up heifers.

Building for the cow

The future: expandable and flexible

Growth happens in stages

All dairies will continue to develop and grow. Growth is not uniform, it happens in steps or spurts.

Extending the barn should be done in logical steps, in terms of labor utilization, labor efficiency and building costs.

Barns with milking parlors need to grow in steps adding one or more groups that take 1 hour to milk. Robotic dairies grow in steps involving one or more additional robots.

This involves adding a new barn section, usually for two hours extra milking or 1 to 4 robots.

How do you grow with a milking parlor?

How do you grow with a robotic milking system?

1:

feed alley

parlor

calving/dry/ special needs/ handling

holding area

Feeding/resting area

Dry, calving, special needs, handling

expansion

Water

milkhouse

Water

1:

Water

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Robots

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walkways

feed alley

Feeding/resting area

Dry, calving, special needs, handling

Water

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expansion

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feeding/resting area group 1

Water Water

Feeding/resting area

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expansion

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Robots Water

example dry cows, expansion

expansion

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expansion

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Dry, calving, special needs, handling

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expansion

feeding/resting area group 1

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retaW

walkways

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feed alley

holding area

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retaW

parlor

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retaW

milkhouse

calving/dry/ special needs/ handling

2:

expansion

feeding/resting area group 2

expansion

Robots

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expansion

Feeding/resting area

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expansion

Dry, calving, special needs, handling

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2:

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expansion

feeding/resting area group 2

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The building block of a parlor dairy is the number of cows you can milk in one hour. There are specific areas for milking, for care and handling and for cow housing (eating and resting).

The capacity to house heifers, and store feed and manure has to grow along with the housing for milking cows. Expansion means the amount of work and number of employees will increase accordingly. Treatment and handling is organized quite differently on farms of different sizes.

When the parlor is fully utilized it must be extended (and the group sizes in the barn too) or you need to build a new barn.

Chapter 1 The four cornerstones of barn design

On robotic milking dairies, there are two options for growth: 1. You make groups of healthy milking cows, and build a separate barn for special needs animals such as calving, fresh cows, and sick cows. Near the healthy cows you only have facilities for quick handling and return to the group.

2. You create barn areas in which you house all types of cows (milking and special needs). The illustrations above show only option 2. The optimum group size for robotic milking is not clearly defined yet. The cow prefers a small group (1 robot, 40 -70 cows). The farmer wants labor efficiency and is likely to choose 2 or 3 robots (80 - 180 cows). From the standpoint of flexibility, it is wise to design large barns so they can work with either small or larger groups of cows.

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The cost: build simple, robust and inexpensive

It’s all about cost per kg milk

Building a barn is an investment, which should involve weighing the costs against the returns and the risks. To do this well you should convert building costs to per liter of milk production. You can express the benefits in the same way.

You can also calculate how much extra production in liters per day is needed to pay for the new investment, or maybe the payback has to come from fewer health problems.

For example, a bedded pack for transition cows. This creates costs in the form of additional barn space, straw bedding and labor for manure removal. But it pays back with healthier cows that calve with fewer problems and a better start to lactation. This improves your labor productivity, and the fertility and longevity of the cows, and reduces your veterinary costs.

Investment plan: Think more broadly than just milk production In your investment planning, include an amount for flexibility so that you can improvise and change some things if needed.

And recognize the value of convenience and a pleasant working environment. With this long term investment, labor savings over the same long term can be considerable, so be sure to value your time honestly and appropriately.

Then apply the same thinking to the barn design alternatives available to you.

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Manure scraper

This V scraper stops outside the barn. As a result, the corner wheels, parked scraper, and manure drop are outside the cow area. This permits better cow movement and reduces foot injuries. The result is lower veterinary costs and labor, and higher production. Because the scraper folds up, you can drive a tractor into the barn, to bed or clean stalls mechanically or to remove sick or dead cows.

Gates

Strategically placed gates make moving and temporary separation of cows very simple. Gates can be used for different things in different positions.

14

Cows must be able to walk around freely and safely. This passage is very narrow and the cows have little room at the entry and exit. The cable, corner wheel and alley scraper make this an obstacle course, with risk of pain and injury. Drinking cows and boss cows can block others from passing through.

Open end wall

You should be able to throw a gate closed and open it with one hand. It should not be bigger or heavier than necessary.

The open end wall and the gates facilitate good ventilation, easy bedding and manure removal, and loading and unloading cows.

Building for the cow

Jan Hulsen grew up on a farm with dairy cattle and finishing pigs.

“Saving 10 minutes of labor every day will save you one and a half weeks of labor each year. With healthy cows and smart work routines you can save even more”

With a degree in veterinary science and a strong interest in animal practice before refocusing on helping farmers sharpen their

Comfortable cows stay healthy and productive. The same is true for people,

critical thinking and observation skills, and increasing their awareness

when they are able to work in a pleasant and uplifting environment.

of the needs of their livestock and other management issues.

Barn design is a process in which several perspectives must be taken into consideration as the project takes shape. These perspectives include the

and wrote the successful series of Cow Signal books. Vetvice is active

costs in check, . It is also important to ensure the barn

in more than 30 countries, providing lectures and training sessions in

design is flexible so it can cope with expansion projects

the areas of Cow Signals, hoof care, fertility and reproduction,

in the future.

management of calves and heifers, dry period and transition management, and building for the cow.

A good barn provides the platform for a successful dairy, and no dairy farmer builds often enough to have sufficient experience in designing and building a

The book series Future Farming® goes beyond the needs of the cow, and focuses on the management of livestock, and people and other

good facility on their own. You should seek the advice of others from a variety of fields of expertise and

Jack Rodenburg, a thirty year veteran in dairy facilities design and

The basic design must be right, as it is virtually impossible to change at a

management in Canada have enhanced the Vetvice team and this

later stage and it is a determining factor in the health and productivity of the

practical guide.

cows in the barn. But the details must be correct as well. If a gate does not swing the right way, or two people are needed to catch and restrain a cow

“An excellent book with many illustrations and compact, clearly written

after all, then you have missed an opportunity to save labor. Building for

text. It provides outstanding information that you can use immediately.”

the cow presents you with knowledge, insight and guidelines to help you develop an excellent barn design. Ideas are presented in clear language, with many pictures, sketches and practical tips.

The advisors and trainers of Vetvice and DairyLogix; this book was based in part on their expertise, knowledge and creativity.

From left to right: Standing: Nico Vreeburg (veterinarian/trainer, barn construction, dairy farm management) Joep Driessen (veterinarian/trainer, Cow Signals Company) Bertjan Westerlaan (veterinarian/trainer, barn construction, dairy farm management) Marcel Drint (veterinarian/trainer, hoof health) Sitting: Jan Hulsen (veterinarian/trainer, large dairy management) Jack Rodenburg (dairy design specialist, DairyLogix)

www.vetvice.com

www.dairylogix.com

feed, water, light, air, rest and space, and health.

As a dairy farmer you should always pay close attention to these needs, in order to ensure good health and welfare and optimum milk production. Building for the cow also demands diamond.

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Jan Hulsen Jack Rodenburg

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Health

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“A barn plan that does not get ripped up at least twice is probably not a good design.”

www.roodbont.com

cow signals diamond. These seven basic needs are

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r

Light

experience, because such advice is essential.

seven key words, which form the corners of the

special attention to the corners of the cow signals

Jack Rodenburg

resources on the modern dairy farm. The insights of co-author

Building for the cow

The basic needs of the cow can be summarized by

Jan Hulsen

co pr py ot rig ec h te t d

With his company Vetvice, Jan developed the Cow Signals® concept

needs of the cow, labor efficiency and keeping capital

Building for the cow

communication he enjoyed three years of on farm work in a large

The cows and the workers should be the priorities in barn design.

The Cow Signals Diamond

Space

About the authors

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