New Farm Dairies 2020

A special supplement by

Spring 2020 Sun Media Ltd 07 578 0030

w 9 ne 2 g m casin w o d far h n S a ed m y sh ts fro dair n e ovem nd nd a impr a l a Ze New ad. abro

Te Awamutu dairy farmers John and Debbie Moorby have been in the industry for the last 35 years, and the concept of a centralised new dairy on their property had been in the pipeline for a decade. Today, they have a new Waikato Milking

Systems 80-bail Centrus composite rotary, fitted out by Qubik TMC, which includes a large feedpad and effluent system. Find out how they planned and built the new operation on pages 42 and 43.

Clever constructions

Moorelands Trust pgs 14-17

Awakeri pgs 18-21

Speake pgs 36-37

Dunroamin pgs 50-53

Clinton pgs 84-85

NEW FARM DAIRIES

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New Farm Dairies is brought to you by...

New Farm Dairies is New Zealand’s most comprehensive guide for farmers planning a new farm dairy construction.

It showcases a range of the newest farm dairies in the country, offering farmers a vital, in-depth reference for their own dairy projects.

We distribute more than 30,500 copies of the FREE publication to all dairy farmers throughout New Zealand, reaching all corners of the country’s vast dairying industry.

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Coast & Country

Building a strong industry If 2020 has taught us one thing, it is how much New Zealand can rely on its primary industries.

For dairying – which has again shown itself to be a big part of NZ’s economic backbone – at the heart of each farming operation is a dairy shed that works day in/day out to get product off-farm and to markets worldwide.

Today, dairy farmers are finding ways to better the way we farm. To work smarter, not harder. And to operate more holistically. No longer do new farm dairy sheds just lift production.

Whether embarking on new builds, full or partial renovations – dairy farmers can improve, change and or alter their total farm system to address what’s not working, and how this impacts on their animals, their staff, their land, the environment and the future of their properties.

That’s why this year we feature a few different ideas around how to improve the dairy shed and the farm.

We’ve met farmers who’ve put much time, effort and capital into projects that represent significant investment but are bringing so much benefit to their operations.

New Farm Dairies’ 15th edition is a truly comprehensive study of 29 individual farm and/or dairy developments, telling each property owner’s unique story and celebrating their tenacity and clever management to make such an investment.

More importantly, it gives those thinking of building new or upgrading current facilities the chance to hear from fellow farmers to agricultural experts on the most up-to-date information, products and services.

Everything from earthworks, building construction, milking plants, to refrigeration, electrical needs to feed systems, equipment and storage facilities, animal housing, to staff accommodation feature in this guide.

Plus, the technology – that measures, monitors and manages nearly all aspects of a new dairy from the comfort of your home or office or the other side of the world in real time – just keeps getting better.

There’s new and innovative ways to store and apply effluent, chill milk, run water systems that deliver efficiency and cost-savings – plus there’s hands-free robotic milking systems too.

Animal health, comfort and production continues to be at the forefront of new equipment and facilities. As is health, safety and retainment of staff. Comfy staffrooms, sound-proofed children’s rooms and showers in bathrooms are complemented by landscaped surrounds of new dairies, offering pleasant work environments.

There’s some no.8 wire ingenuity packed in, and bespoke ideas flavoured by dairies seen abroad. And, again this year, nearly every farmer we interviewed had read New Farm Dairies as part of their research into crafting their new facility. Their biggest piece of advice? Research, research, research!

So enjoy this edition. And thank you to 2020’s contributors for welcoming us onto your farms and sharing your stories – you’re about to inspire others embarking on the dairy-building journey.

Those wanting to feature in next year’s edition – please get in touch today with our advertising consultant Lois Natta on 06 342 7773. She’s project-managed NFD for more than a decade, and can help with all advertising needs. But be quick – space fills fast.

Claire and Brian Rogers, Publishers

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NEW FARM DAIRIES

Choosing your dairy site is key

Are you mulling over the idea of an upgrade to your existing dairy shed? Maybe you’re thinking of building new? Or your current set-up only really requires a small renovation or partial tweak to certain infrastructure to meet your needs.

Soil type, strength and stability, risk of erosion, slips or slumping and any hydrological issues such as groundwater or flooding risk should be assessed. Soil types such as peat pose design challenges and risks.

Optimise the race and dairy layout for cow flow and functionality. This is of prime importance. Poor cow flow can lead to a number of issues including stock bottlenecks and excess effluent generation, as well as ongoing frustration for staff.

Whatever type of project you’re thinking of, it is vital to put Having open sides on the north-east/north-west sides will assist as much research as possible into the design of your project – because this will ensure the end result nails what you wanted to keeping the inside dry and free from algal growth but be mindful of the prevailing wind and impact on cow and milker comfort. achieve from your investment.

And remember, the tanker track and tanker park area will On their website, DairyNZ has a page to guide you through need to meet dairy company requirements. the considerations and decisions required after deciding on Consider proximity the type of dairy and to three-phase power, yard, and sizes. “Key adequate potable elements to get right water supply and other are the location of the amenities as these can dairy on the farm, the be significant costs. design of the dairy Ideally, the site will and that each step have room for all curof the build is done rent facilities as well as in sequence. growth in the future.

“Choose the best site Preferably effluent available for the dairy DairyNZ’s website landing page. from silage stacks, – as the site will dictate feed pads, wintering barns, and any other areas where there a lot of the design options, and have a significant influence on is effluent accumulating will be able to drain into the dairy’s the build cost.” effluent storage pond (utilising natural fall and gravity will save Here are some of the factors to consider for the proposed pumping costs). dairy site from DairyNZ. You may wish to expand the dairy, yards, pad areas or ponds in A new farm dairy or alterations to an existing dairy must be assessed to ensure compliance with NZCP1 and other relevant future and you’ll need plenty of room for vehicle access, includrequirements. The site suitability, premises and plant must be ing stock and supplementary feed truck turnaround points etc.

Consider adding these facilities into your initial design – even if assessed by a farm dairy assessor prior to work starting, and you have no immediate plans to go ahead with them. on completion of the building, before milk can be collected See more information about dairy design at: https://www. for supply. dairynz.co.nz/milking/new-dairies-and-technology/blueprintsFor some sites, it may be wise to seek geotechnical advice to and-building/ assess the site suitability for the building and pond placement.

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WILBROOKE

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Coast & Country

Big efficien

gains Merle Cave

The Garrett family: Craig and Phillipa with sons Josh and Alex.

The new herringbone has sped up milking times, and is a pleasant environment to work in.

Pongakawa farmers Craig and Phillipa Garrett, with their school-aged sons Alex and Josh, live on their 230ha ‘home farm’ just down the road from their 120ha ‘second’ farm called ‘Wilbrooke’.

never had cup removers or a meal feeding system here,” says Craig, who is impressed at how much efficiency and labour gains the new shed has brought.

“The old shed was tight on space and cow flow was horrible. As such, it was a very slow shed to work in. It took about 45 minutes longer to milk in.”

Wilbrooke, on Old Coach Road, is a 105ha effective milking platform with 300 Friesian cows. The Garretts have owned Wilbrooke for 15-odd years. “The old shed was very tired.

We knew when we bought this property the shed would need upgrading at some stage,” says Craig. “We just kept nursing it along until that day came.”

In April 2019 the old shed was demolished to make way for a 32-aside herringbone. “We’ve

Good reputation Craig wanted to futureproof the operation and provide a good workplace for staff. He hadn’t dealt with Don Chapman, but found some Chapman-designed sheds nearby. So he went for a nosey. “I talked to people about their experiences with them, how they found the sheds and how Don’s business was to work with.

“I didn’t hear any bad comments, so we got

Don Chapman Waikato Ltd built the new herringbone to fit amongst existing infrastructure, such as raceways and a nearby implement shed.

them to quote the shed in August 2018.” With more than 40 years’ experience, Don Chapman’s dairy parlour designs deliver greater farm efficiency and profits.

Shanan White, who owns Don Chapman Waikato Ltd in Morrinsville, has built many Chapman Dairies. Craig needed someone who was going to deliver on time. That person was Shanan. “I found Shanan very approachable, very knowledgeable, and the price came in thereabouts with others so we were happy.”

Shanan’s team built the 32-aside from scratch on the former shed site to utilise an existing effluent system. “Plus, here is the best road access for tankers,” says Craig.

With the old shed demolished mid-April 2019, Shanan’s builders turned up soon after.

Shanan says the building is standard size for a

32-aside – just over 28m long with an 8.7m roof that covers the animal-handling area and AI race, with a milk room, large storage room, and small office/electrical switchboard room.

At design phase, Craig asked for a large storage area and extra width around the feed system “so people can walk down to look at eartags and don’t have a feed system hard up against them”.

Standard detail Shanan says they’ve since made this detail standard in all Chapman shed designs. “Craig’s construction went well – the only challenge was fitting the shed into the right place to utilise nearby infrastructure. The dairy was a tight fit with sheds nearby but we managed to still make his races to the shed work.”

Since 1976

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WILBROOKE

PH 07 578 0030

Wilbrooke is the Garrett family’s second dairy farm at Pongakawa.

New contract milkers Stacey and Kris Brown, Camco Dairy Service’s Gary Wood and Mark Jamieson, Witheford Electrical’s Shayne Reid, with Pongakawa farmer Craig Garrett, son Alex, wife Phillipa and youngest son Josh.

Shanan’s key advice is to get your prospective dairy shed builder involved in your plans as soon as possible – so complexities can be identified and worked on early on. “For those building replacement sheds, try to work the new shed into exiting race layouts and orientation, and examine how close the existing power source is, as it can be expensive to put in new mains power. You have to weigh up cost versus benefits – whether some things are worth doing for the expense, or aren’t worth the hassle.”

The build was complete for the first milking on July 16, 2019. New contract milkers Kris and Stacey Brown have no idea of past struggles, but they do appreciate milking in the new dairy. “At first the first cows would see the meal and stop. Now they come right to the front and it just flows. Raw milking time is only

1.5 hours; that’s putting 300 cows through, so it’s quite a speedy shed but it’s good for the animals as well,” says Kris.

One brand Craig chose a Waikato Milking Systems plant, so turned to local Waikato authorized dealership Camco Dairy Services Ltd at Reporoa.

“Our previous contract milker had worked with Camco, so he recommended them.

“We’d put a Waikato plant in our home shed so wanted to stick with Waikato. When we talked to Camco, they promised they could deliver on time – that was key for us.”

Camco owner Dave Goddard put a crew on and got the job done. “Even though they ran a bit late getting here, they worked weekends to ensure it was done on time,” says Craig.

Loyal sparky Shayne Reid of Witheford Electrical.

Camco Dairy Services Ltd manager Gary Wood says they installed the milking plant from the pit back into the milkroom, and the underground water system.

Before concrete was laid, Gary met with Craig to see where he wanted water ports. “Then we could ascertain where to put water pumps, to run everything underground.”

Then came the plant. “The first thing we do is install the slug or milk line, or the carrier rail.

Everything leads from there. The next important job is positioning the cups in the right place. If too far forward, or too far back, they will not line up with the cows.” Once the plant is running Camco machine test it to ensure everything is working as it should.

The Waikato Supa4 plant is known for its fast, clean milking characteristics and simplic-

Calves on Wilbrooke are fed Sealeswinslow’s Calf Range products.

ity. It has a large single 100mm milk-pipe draining into a receiver at one end of the pit.

It’s impossible to flood, and with modern electronic pulsation milking is fast and uninterrupted. The milking machine is powered by a vacuum pump with a variable speed drive to save on power use.

Waikato’s electronic cup remover is made from high-grade stainless steel and offers a high performance system designed to reduce labour costs. Operated from a central Master Controller, settings can be adjusted to suit. Gary says electronic cup removers give farmers ability to reduce a labour unit from milkings. “And electronic cup removers can be refitted to an existing shed no problem at all – anything will handle it.”

4

WILBROOKE

Page 6

Coast & Country

This is the second shed in which the Garrett family has installed a Waikato Milking Systems plant.

Waikato’s electronic cup removers have made milking at Wilbrooke much more efficient.

Camco also takes on farmer-requested tweaks – so the end product always suits their milking situation. Craig asked Camco for a tap fitting to allow staff to take milk from the ‘calf vat’.

“So together we built it how Craig wanted it.

He can do the wash as normal, or drain it if needed.” Craig also wanted to use this vat for chilled water for plate cooler secondary cooling.

“We plumbed it to do that job for him as well.”

Washdown controller The plant’s washdown controller is from Sema. Founder Maurice Coates says all of Sema’s WPCs have the following features. Loss of prime protection is built in. “If the pump runs dry it will stop and a message will appear on-screen saying it has stopped for that reason.”

They have a maximum ‘run time’ timer. “If enabled, this timer will only allow the pump to run continuously for the number of hours entered before it will stop and display a message to check for leaks.”

The shed has Waikato’s smartPULS pulsators.

A set of Waikato cups.

The Sema washdown controller.

And two pressure set-points can be switched between with a digital input. “And an input is dedicated to monitoring optional external interlocks – for example, low tank water levels.

“Just like our milk pump controller, all parameters can be adjusted without stopping the pump. Plus, the revolutionary ‘ripple control’ software uses the rate of pressure drop to determine how much water is used and whether the pump should continue to run or not.”

Sema manufacture variable speed milk, water, vacuum and effluent pump controllers in all sizes up to 250kw. “We test every function on every controller before it is dispatched, then test them all again.” Maurice says Sema controllers are design to run in rural environments “that are typically wet, with bad power”.

Craig supplies Fonterra, who got him a 4100L vat for calf milk. DTS fabricate, engineer and supply high quality food grade vats to Fonterra. “Our vats are made in NZ in accordance with MPI standards, and we offer

a full turnkey service that includes design, manufacture delivery, installation and ongoing maintenance,” says Sarah Middleton of DTS. The in-shed feeding system was Craig’s first one. Hamilton-based Livestock Feed Systems installed the meal feed system. An 80m coreless auger pumps feed into individual bins in the bails from a silo outside.

“We installed this to get away from incurring damage in paddocks. Also, it takes away the labour factor of towing trolleys etc around paddocks – saving staff time.”

Craig believes in-shed feeding also keeps quality of feed products intact and offers variability in what you can feed. “And outside you can’t control allocations either.”

Livestock Feed Systems owner Mike Barrett says the system offers numerous benefits but first is animal health. “Every cow receives her fair share of product.”

Mike’s business manufactures and installs the

systems into herringbones and rotaries. “We assemble silos in Hamilton and transport them to site. We also install the systems and have never had an issue fitting one yet – and we’ve done very tight spaces to open-plan set-ups.”

Mike says in-shed feeding is very popular.

“Nearly every farmer we’ve installed one for says they should have done it years ago.” Craig recently got Mike back to install an in-shed feed system into his home farm cowshed.

Loyal, reliable sparky Craig awarded the sparky work to Witheford Electrical, which he’s called on for 15 years – first via founder Kelvin, now new owner Shayne Reid.

“They’ve always given us great service on the jobs no-one wants. Whether it’s Boxing or New Year’s Day, if you ring Shayne he’ll turn up – if a guy will do that for you, then you’re more than happy to give him the big jobs,” says Craig.

Authorised Dealers

Phone 07 333 7304 For further information, contact Dave Camco Dairy Services Ltd 222 Reporoa Road, Reporoa dave@camco351.co.nz www.waikatomilking.co.nz

For further information, contact Dave Camco Dairy Services Ltd 222 Reporoa Road, Reporoa dave@camco351.co.nz www.waikatomilking.co.nz

PH 07 578 0030

Page 7

WILBROOKE Fonterra supplied a second ‘calf vat’ to Craig Garrett, which was manufactured

by DTS. This second vat is also used to chill water for plate cooler secondary cooling.

The new herringbone has brought efficiencies to Wilbrooke’s dairy farm.

The feed system, installed by Livestock Feed Systems, enables each cow to be individually fed, promoting animal health.

The feed silo.

Manufactured, transported to site and installed by Livestock Feed Systems.

Shayne disconnected power to the old shed, then connected power from the roadside power pole to the new dairy. “Then I completely wired the shed, including switchboards, machinery, lighting etc.”

Craig requested Shayne hardwire the feed system so its sensors can’t go off at night and dump/waste feed. “Now, when the shed’s turned off, no feed can come through.”

Shayne’s only challenge was limited power supply. “This site has 60 amps; most builds have 100 amps. We’ve put everything we can on VSDs, which limits power use, and by locking the water heaters out when milking we’ve kept it well under 60 amps.”

Saving water Craig also purchased a Dungbuster from Technipharm. “It washes the yard by itself and has been working well.”

Technipharm CEO Harmen Heesen says dealing with effluent at the source is always more cost-effective than after its created.

“For that reason many farmers install a Dungbuster Automatic Yardwashing system.

“Reducing water use is high on the agenda with Dungbuster, and where conventional yard washing may take up to 10,000L to 20,000L – with Dungbuster this is reduced to a mere fraction of that volume.

“Take a yard that’s 60m long and 12m wide, enough for 500600 cows. It would take Dungbuster with an 8m-per-minute traveling gate eight minutes to wash the yard and with a water use of 300L per minute – a total 2400L water. That’s a significant reduction.

Plus, no labour is needed to wash the yard. “This is another significant saving in time and effort and means more important profitable tasks can be completed on-farm or create more ‘free time’ to relax and recharge,” says Harmen.

The effluent pond is emptied by JC Slurry Spreaders Ltd. Owner-operator James Wilson offers pumping and stirring services to the Western Bay of Plenty, and can pump up to 900m from a pond. “James contracts on both farms to undertake effluent spreading, as we haven’t got fixed systems,” says Craig.

“We’ve kept our two ponds and continued our eight-year rela-

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The Dungbuster Automatic Yardwashing system saves on water use and labour.

tionship with James to spread effluent, when required. We only pump when ground conditions are right.”

Craig has about 90 days’ storage, but with water diversion now in place freshwater can be diverted to pasture which has extended storage capacity.

Calve feed Calves reared are fed Sealeswinslow’s Calf Range products. TSR Central & Eastern BOP, Mark Mellsop, says the range includes NuStart Milk Additive, a unique gut conditioning package.

Benefits from including NuStart is it stimulates appetite, digestion and absorption of nutrients; enhances rumen development; encourages growth of good bacteria while preventing bad bacteria and minimises disease challenge. “These factors also help improve growth rates.”

The products have a coccidiostat, (Bovatec), to prevent coccidiosis; great taste so calves continue eating; and contain high quality proteins, and vitamins and minerals. “And they don’t contain fillers such as PK.”

WILLOWDENE FARM

Page 8

Coast & Country

Clever system Steve Edwards

The Boyle family – Caroline, Keith and Jonathon.

The finished article at Willowdene Farm.

‘Do it once and do it right’ was the philosophy behind a new dairy shed in the Bay of Plenty.

With a long farming history in Pongakawa, the Boyle family believe they have achieved a top class result with their 44-aside herringbone operation on Maniatutu Rd. The concept was simple, merge two adjoining 150ha properties and their respective herds and dairy sheds into one operation milking 600 cows.

The husband-and-wife combination of Keith and Caroline Boyle own Willowdene Farm and neighbouring Four Oaks Farm – the latter in Caroline’s (Benner) family for more than a century.

Son Jonathon Boyle has a share in Four Oaks Farm, while contract milking and is an equity shareholder in the combined operation.

Jonathon says they’d been thinking about the single shed concept for a few years, with the existing operations reaching their use-by date in meeting industry regulations for aspects such as refrigeration and effluent disposal.

Using the latest technology, Jonathon says the design also gives some leeway for potential future expansion.

Forward planning

The decision to go ahead with the project was made in early-2019, with an existing shed site chosen over the other “for convenience” and better access to water and electricity supplies.

Jonathon says they tossed up between a 40-bail or 44-bail herringbone, opting for the larger model after receiving some professional advice and again to allow for future growth.

The new shed was built on a “natural hump” on the property, with 20,000 cubic metres of material taken out and replaced by rhyolite to improve drainage.

A larger lead-in for the Friesian herd was incorporated in the design, so less mud and effluent are brought into the yard.

Long-lasting stainless steel was used

The yard built by Don Chapman Waikato. throughout in the shed’s tanks and pipes. The dairy shed was designed by Morrinsville-based Chapman Dairy.

Director Don Chapman says the property owner asked for some enhancements to the traditional 44-aside herringbone concept plan.

At Pongakawa this included a larger cow entry and yard, plus double backing-gate systems, and staff walkways along both sets of bails. Don Chapman’s design also included a bigger-than-usual plantroom.

Site meeting Following a site meeting of contractors, physical work began in early-April 2019. Building was undertaken by Don Chapman Waikato, based in Morrinsville, with three staff on-site for 10 weeks.

Construction consultant Don Fowler says

while the 44-aside herringbone project was “pretty standard”, some significant tweaks were made to allow for potential expansion of the milking operation in future.

This included a bigger office area and pumpshed, with the yard covering 706 square metres and a radius of 15m to allow for an increased herd size if desired by the owners. “A larger entry race allows cows to clean their feet on their way in,” says Don. The bails are halfa-metre wider than standard to allow for milkers reading cow eartags on one side and feed troughs on the other. “There is a good flow for the cows entering and leaving the milking shed,” says Don.

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Don Chapman Waikato construction consultant Don Fowler.

The Protrack Draft gate from LIC Automation.

Milking and water systems at Willowdene were installed by Te Puke-based Think Water Bay of Plenty. General manager Angus Clarke says the Boyles wanted a well-built, long-lasting system.

Following initial underground work for required milk and water inlets and outlets, Think Water BOP put in the central milkline after the bails had been erected. “Up next was installation of three 25,000 litre water tanks, supplied by a good existing bore,” says Angus.

High spec Variable speed drive pumps installed by Think Water BOP, cover aspects including washdown, milk cooling and shed supply. The room also houses a cow-dosing unit linked to the shed water supply system.

Think Water BOP installed the vacuum pump, supplied by GEA Farm Technologies. Angus says the heart of the shed is “very high spec”.

His team undertook plumbing work for the shed’s two milk vats, plus piping and

Page 9

WILLOWDENE FARM

Think Water Bay of Plenty dairy & pump technician Iain Watson and general manager Angus Clarke.

SealesWinslow animal nutrition technical sales rep Mark Mellsop.

Dobsons’ Refrigeration & Electrical key account manager Stu Walker.

Bails have been made wider to accommodate an in-shed meal feeding system. installation of the associated chilling unit.

The milk room features a plate cooler and two 600L hot water cylinders, along with the ‘electronic brain’ for the automatic washing system, all installed by Think Water BOP and supplied by GEA. Both companies played similar roles in the plant’s automatic teat spray and cup-removal operations, with Think Water BOP also providing design aspects for the associated effluent disposal system.

GEA area sales manager Paul Convery says the Boyles wanted a “one-stop shop” which could supply and install everything, “The Boyles also stipulated that they wanted a high-tech futureproofing system that they could add anything to without ripping half the gear out.”

GEA supplied the iXpress Plus Milking system with iCORE that has “all the associated bits ready to add any other equipment to”.

With the iCORE system installed, Paul says

the Boyles can pretty much add anything to this system. “It is the brains for each bail and can handle a lot more equipment than is already installed.”

Paul says GEA is pleased to have a piece of equipment that allows the company to futureproof its systems so clients don’t have to throw away good equipment when they want to upgrade to something new.

Smart system A new two million litre effluent pond was constructed, fed through a stone trap from the cowshed that has a Dungbuster system supplied by Technipharm in place. Electrical work at Willowdene was conducted by Te Puke-based Dobsons.

“It’s a very clever system,” says Dobsons’ key account manager Stu Walker. Dobsons undertook the switchboard design, along with

flow monitors on the water tanks, plus wiring of the vats, chiller controls and feed systems to a central control panel.

“With the quality of product, it was a great project to work on,” says Stu. “It is also very serviceable.”

Dobsons also wired in the security camera system at Willowdene.

Mount Maunganui-based GEA’s FIL supplied the chemicals and emollient for the respective milkline cleaning system and automatic teat spray.

Bay of Plenty area manager Fraser Stewart says an acid/alkali/chlorine mix is mixed with hot water and pumped through the milk-lines in the computer-controlled system.

“The teat-spray also uses an automatic mixing unit, with emollient and water ‘fired up’ as a cow crosses a sensor unit after leaving the bails,” says Fraser.

WILLOWDENE FARM

Page 10

The shed taking shape.

Early days of construction.

A road-side view of the Willowdene Farm dairy shed.

Rubber matting placed on the exit race and in the pit was supplied by Numat Industries from Oamaru.

Feeding An in-shed meal feeding system was installed

by Matamata-based Buster Cover.

Foreman Bill King says two 16 tonne silos house the bulk material, which travels along a 90mm PVC pipe to a stainless steel trough along one side of the bails.

“The material is ‘dragged’ through the pipe via a spring auger powered by a 1.1kW motor.”

A control system in the pit monitors how much feed each cow receives during milking,

BUSTERCOVER

Ltd

This is a heavy-duty material, with steel wire inside, tailored to go over a gravel base and compensate for a lack of concrete underneath.

Anthony says it is traditionally used in ‘high wear’ transition areas for cattleFEEDING near yards, HERRINGBONE IN-SHED which can be worn out with use if not covered.

“Laid in rolls, the matting helps prevent lameness in cattle and protects the surface it covers.

“Cows leave stones on the matting and not in the yard, which can also cause lameness.”

Ergomat was used in the pit, which Anthony says has rubber studs on the under-side to aid staff comfort.

“Matting in both areas of the Willowdene shed is secured via a stainless steel anchoring system into the base surface.”

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The Willowdene design includes an extended AI/vet race and in-bail feeding system, while rails along the pit walls allow milkers to easily check out cow eartags for identification purposes relating to artificial breeding and healthcare.

Anthony Garton says Zigzag matting was used BCL Feed Systems on the laneway.

with a sensor indicating that the trough needs to be re-filled for each new row.

Bill says the amount of feed dispensed can be changed – up to 4kg per cow each milking – as required.

The cows’ tasty treats at Willowdene were supplied by Morrinsville-based SealesWinslow.

SILO’S 2T-45T Animal nutrition technical sales rep Mark Mellsop says cows each receive 1kg of feed at each milking through winter and 3kg-4kg last summer due to the drought, with the mix changed according to the different seasons of the year.

For example, after calving the Willowdene herd was fed a starch blend – 70 per cent pellets and 30 per cent loose feed. “You want to start the season with high energy/high starch,” says Mark.

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The new shed was built on a “natural hump” on the property, with 20,000m3 of material taken out and replaced by rhyolite to improve drainage.

The new dairy shed boasts a Protrack Draft gate from LIC Automation. This is controlled via an app on a smart device or computer on Willowdene Farm, which runs the Protrack automated three-way drafting gate.

LIC Automation national sales and product manager Jason Quertier says the app can be used in the shed or the paddock, and the list of animals is synchronised with MINDA LIVE. “Drafts can be scheduled for the future or at next appearance at the gate,” says Jason.

“An electronic reader and antenna identifies an animal by ear tag number as she walks into the draft gate, which checks to see if the animal is to be drafted and in which direction, with information fed to the farm computer and Jonathon’s cellphone.”

Jonathon can also use simple reports to see if any animals were missing from milking, and

Coast & Country

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Page 11

WILLOWDENE FARM

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ORCHARD

Page 12

Coast & Country

Herringbone happiness Bridget Jochems

Peter Spiers Electrical Ltd’s Peter Spiers put in the power for the effluent pumping system.

Dennis Orchard cleaning his boots in the boot cleaner put in to prevent disease spread.

The new 30-aside herringbone dairy on Dennis and Anita Orchard’s 100ha Waihi farm has been in the pipeline for more than a decade.

“We bought our first farm in 1987, it was 50ha and we milked 120 cows. We built our herd up to 150 cows over time,” says Dennis.

“In 1999 we bought the neighbour’s 50ha and milked another 120-cow herd, also building it up to 150 cows. We farm a simple, low-cost operation. We grass-farm and make our own silage. And we’ve been operating the two farms as separate entities until this season.”

Dennis and Anita wanted to consolidate the operation and run it as one farm and in 2008 plans were drawn up and consents were gained for a new shed. But Dennis had a bad feeling about going ahead with it, which was good intuition as it was just before the global recession.

The DeLaval MidiLine ML2100 is a great system for future expansion if required, says De Laval’s Malcolm Kensington.

Ten years later, the 30-aside herringbone was built 100m down from the original shed as this site was the most convenient for power and tanker access.

Good run “Building this shed has been really rewarding because it works well,” says Dennis. “We had plenty of great people who went the extra mile and know what they are doing working with us. We felt lucky to have our son-in-law Steve Mathers and our grandson Corbyn Mathers help at the very beginning with the siteworks and Corbyn’s 13-year-old brother Ashton Mathers was great with fetching and carrying.”

“Another grandson, Regan McCowatt, came home from Australia for six weeks to help with the building,” says Anita.

The Orchard cowshed was the first job that Corbyn did working for his father Steve Mathers of Steve Mathers Contracting. The site required

DeLaval’s Malcolm Kensington and Waihi Farm Services’ Steve Barnett checking their workmanship at the Orchard dairy.

a large excavation, a small extension to the tanker track and a new tanker loop. “We used lasers to measure the dimensions and height. It was important that we got it right for the next guy. You also don’t want to use more concrete than necessary, and we didn’t want to be in the position of putting dirt back,” says Steve.

Rex Podmore from Brownmore Construction in Waihi found it advantageous that the shed was built over a longer time than the usual, in-between the season’s rush. “We could choose our days and I was able to lay concrete without working around other contractors. Dennis and Anita concreted under water tanks and in the surrounding area of the shed too, which makes keeping things clean and tidy easier.”

Matt Walker Builders of Waihi constructed the 32-metre long shed with insulated panel for the exterior cladding and a colour steel roof. “The shed is designed and built with much consideration being given to milkers’

The DeLaval Set-up.

requirements and futureproofing the shed,” says Matt.

“Rooms include an office/staff area, toilet, milkroom and storage room. Space for future meal feeders has been allowed for – as has room to add another five sets of cups should the need arise in future.”

Bigger and longer Matt says they started the building work on a green site, and there were a couple of things Dennis wanted changed along the way. “He wanted a bigger dairy area, a longer pit and a bigger yard than what was on the original plan, and we were able to accommodate this. I enjoyed the building help from their grandson Regan.”

Mark Hutchins from Hutchins Engineering in Waihi was involved from the start of the project. He took care of all the pipe welding work in the yard and the pit and installation of the pendulum gates.

PH 07 578 0030

Page 13

ORCHARD

The Orchard dairy shed was the first job Corbyn Mathers did working for his father, Steve Mathers Contracting.

Farm worker Gerry Whare, the Orchard’s son-in-law Steve Mathers and grandson Corbyn Mathers, farmers Dennis and Anita Orchard, Brownmore Construction’s Rex Podmore, Hutchins Engineering’s Mark Hutchins, Peter Spiers Electrical Ltd’s Peter Spiers, Waihi Farm Services’ Steve Barnett, Dairy Technology Services’ Dave Gray and DeLaval’s Malcolm Kensington.

The original cowshed.

The Orchard’s new cowshed was in the pipeline for more than 10 years.

There is a double backing-gate system so two herds can be in the yard simultaneously. Each gate is 14 metres, giving the circular yard a 28m diameter. The yard has been constructed on the generous size in case the herd increases in size at a later date. There are drafting pens on either side of the bails for ease of sorting cows and a vet-race with a drop-down rail.

The power from the transformer by the original shed was brought to the new shed by Peter Spiers from Peter Spiers Electrical Limited.

He did all of the electrical wiring required; the milking plant, lighting, effluent pump and the power to hot water cylinders. “As this shed is just down the track from the original shed we only had to bring the power a further 100m, which

was efficient,” says Peter.

Dairy Technology Services’ Waikato area sales manager Dave Gray has done a good job futureproofing the shed with regard to refrigeration requirements, say the Orchards.

Futureproofed refrigeration “DTS supplied and installed a doublebacked plate cooler that will run chilled water through to cool the milk, and the refrigeration unit that we’ve installed cools both the vat for the milk and another vat, which holds water for running through the plate cooler,” says Dave.

Steve Barnett from Waihi Farm Services and Industrial had only just bought the business

when he was asked to do this job.

“It was quite a big job to start on, DeLaval’s district sales manager Malcolm Kensington was really helpful with the whole job, not just because this is my first cowshed but also because that is just part of their service,” says Steve.

Low input system Malcolm says the DeLaval MidiLine ML2100 that Dennis and Anita chose is a low input batch milking system. “The clusters are positioned in the middle of the pit and swing over to both sides, it is easy and smooth for milkers to use.

“It is a modular system and so is easy to

Contract milkers Adrian Healy and Jess Doller say it’s a great shed to milk in.

expand on, if more cups need to be added,” says Malcolm.

The Orchards have also put in a maintenancefree iron extractor system. This was imported from Australia; Steve’s background as an electrician in the mines helped him decide what system would work best. “There are many advantages to it; it doesn’t need back-flushing and it doesn’t need any chemicals.”

Dennis and Anita have put in the iron extractor system for the shed water at this stage, but when it proves itself to be maintenance-free they will put a bigger one in for all farm water.

“We are still in the process of converting the two farms into one operation; the new cowshed was just the first part of it,” says Dennis.

Page 14

MOORELANDS TRUST

Coast & Country

Life-changing

The Quintin Oakes Builders-built shed viewed from the yard.

Josephine Reader

Taranaki farmers John and Jannine Moore are very happy with their new dairy.

A brand new dairy shed with easy-to-use, featurepacked milking technology is changing life on the farm for John and Jannine Moore.

The new 50-bail rotary fitted with the latest Dairymaster milking equipment replaces an old 32-aside herringbone shed that had served the property for more than 20 years.

Milking time has been slashed from up to seven hours a day, to around four-and-a-half hours, and outside AB and mating time, just

one person is needed in the shed.

The Moores started out with 50ha, and over time have expanded the farm to 172ha, driving the need for a better shed which was more centrally located on the 154ha effective central Taranaki farm, just outside Stratford.

Due to surrounding swamp, the right spot for the new dairy ended up being on a large hill. Hinton Contracting – the Moore’s regular agricultural contractor – provided tractors and trailers to move the tonnes of dirt excavated to make way for the new shed.

Eltham-based Uhlenberg Haulage took care of removal and other cartage needed for the build. Uhlenberg, a family-owned company that’s been around since the mid-1960s, takes pride in being staunch supporters of the local

community, which was a good fit for Moores, who chose their contractors to include as many local firms as possible.

Daryl Uhlenberg says it was great to work with John and Jannine, which was a sentiment echoed by many suppliers involved with the new shed build.

GJS Plumbing Stratford looked after the plumbing and drainage work for the new dairy.

Impressive design Local Chapman Dairy agent, Quintin Oakes Builders, got the nod to build the new shed.

Using Quintin was an easy decision for the Moores because Quintin had built a new dairy for their daughter and her husband a couple of years earlier, and they were impressed with the design.

Groundworks started in February 2019 and cows were milked through the new shed for the first time in early-October 2019.

John liked that the Chapman Dairy shed design was spacious, and that all corners of the building were utilised: “There was no wasted space.”

The unique roof design includes polycarbonate panels on the central section and a ventilation panel, which introduces fresh air into the parlour – while also excluding birds – improving air circulation and providing a more comfortable environment for milkers and cows.

“We took on the job with a handshake,” says Quintin. “John and Jannine are those sort of people. The build went very smoothly, and they were great to work with.”

Page 15

MOORELANDS TRUST

PH 07 578 0030

The Chapman Dairy shed design includes a ventilated roof that excludes birds.

The Dairymaster SwiftFlo Endurance milking technology offers detailed information on individual cows for better decision-making.

The Moores and their team: Farm workers Luke Scherrer and Mason Dyer, and farm owners Jannine Moore and John Moore.

A height-adjustable platform provides a comfortable standing surface for the milker.

The modern dairy includes all of the expected amenities – a family room, dedicated vet area, kitchen and storage areas – which, when the time is right, will make it easier for John and Jannine to step away from the daily routine of milking and leave it in the hands of a sharemilker or contract milker.

In the meantime, John, Jannine and their current farm team, Luke Scherrer and Mason Dyer, are making the most of the new dairy, and the smart Dairymaster herd management and milking equipment that features in the shed.

Improved health monitoring MooMonitor takes the guess work out of heat detection, and also gives farmers an easy-to-use tool to monitor cow health, says Dairymaster national sales manager Shaun Dyer.

John reckons the MooMonitor system is one of best things about their new dairy. “The monitors are like an unpaid labour unit.”

With data at your fingertips about how much resting time each cow has, time spent feeding, rumination, and activity time, the system provides farmers valuable insight into cow wellbeing, says Shaun.

John has seen value in the MooMonitor technology almost immediately – with the system flagging cows with unusual behaviour – off their milk, high resting rates, low feeding time – which has facilitated early detection and treatment of issues such as facial eczema.

Inside the shed, the Dairymaster Swiftflo Endurance system is saving time and effort. All milkers agree that the divert line is one of the new dairy’s best features. Cups are automatically sanitised between each cow, enabling milk to be diverted to the colostrum tank at the touch of a button.

“The divert is super-easy to use. Just press the button on the bail, and it’s done. It’s great in spring, and for any bucket cows,” says Mason. “It wasn’t that expensive to add and it’s really a great thing to have,” says John.

On the cups-on side of the shed, a hydraulic platform can be raised or lowered to better suit the height of the milker, and as well as being a real back-saver, it also provides a more comfortable standing surface, which is great, says Luke.

Dairymaster research shows that cows are typically milked one minute faster compared to other systems, says Shaun. “And the way the system mimics the natural milking cycle of a calf helps let down and milking speed.”

The other great thing about Dairymaster technology is it works

together seamlessly, making it easy to use and can be installed in one go as the Moores have done, or added to as budget allows, says Shaun.

With milking time reduced by one-third, automated plant wash, walk-over weighing, preferential feeding capability, automatic drafting directly from the bail, automated teat spraying from on-deck units and more – it is easy to see why the new shed has been life-changing for the Moores and their team.

But it’s often the simple things that give the most joy, and for Jannine the shed hose is one of her favourite things in the new dairy. The hose is mounted on a rotating boom above the platform, and moves freely for easy cleaning. “I don’t have to lug around a heavy hose, and it’s never lying on the ground to trip over,” Jannine says.

Easy washdown Specialised paint coating on concrete parts of the wall and floor surfaces not only make keeping the dairy clean easier, it also protects the shed’s concrete surfaces from harsh shed chemicals.

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Page 16

Jono Keegan from Keegan Electrical checking out the book with key information that they left for John and Jannine.

MOORELANDS TRUST

FIL’s Craig Allen checks up on the FIL Auto mix + spray unit that delivers teat treatment to the on-deck teat spray units.

The team from DR Jack Gray has been applying the protective paint coating to dairy sheds for many years, and it is a product that features in many sheds around the province.

A Technipharm dungbuster is fitted to the backing gate, cleaning the yard as it moves. Plumbed into the yard’s water supply, hundreds of water jets and a rubber scraper remove the muck as the gate moves around, so before the last row is finished, the yard is clean. This Dungbuster is a real time-saver and also uses significantly less water than simply hosing down the yard, so it’s a win-win, says John.

FIL’s Auto Mix + Spray unit eliminates another task for the milking team, automatically mixing FIL Teat Conditioner and FIL Iodoshield Active teat spray to the right ratio, for delivery via the on-deck teat-spray units, says FIL area sales manager Craig Allen.

“The system eliminates human error and is synced to plant start-up, making it really easy to use,” says Craig. Changing the ratio is done via the easy-to-use display, and an orange flashing beacon gives a visual alert when the drums are getting low.

Coast & Country

Taranaki farmers John and Jannine Moore with their contractors; builder Quintin Oakes, FIL’s Craig Allen and Keegan Electrical’s Jono Keegan.

Concrete surfaces painted by DR Jack Gray make it easier to keep the dairy clean.

Quantum Red, Quantum XL and C3 are used in Dairymaster autowash system to keep the new milking plant in top condition.

A relatively new DTS glycol chiller unit was moved from the old shed to the new dairy. It was a good chiller, according to John, and he was keen to retain the unit, which was provided

by DTS. DTS supply, deliver, install and commission refrigeration systems throughout New Zealand. The unit provides extra cooling capacity to support the double-bank cooler, which takes care of milk pre-chilling. A DTS silo wrap provides extra insulation on the primary vat. And a DTS Patton Pak unit provides chilling on the smaller colostrum silo.

One-stop electrical shop The team from Keegan Electrical, who have done work for the Moores for years, completed the electrical fitout – including moving the refrigeration unit from one shed to the other. The

electrical work was led by sparkies Adam Kerr and Cameron Keegan, who did a great job, says John.

Keegan Electrical owner Jono Keegan says the attention to detail in the electrical work inside the dairy – like equally-spaced fastenings on the conduit, the tidy, well-labelled switch box and many other details –“are the among the reasons clients like the Moores keep getting us back to do their work”.

Keegan Electrical is also accredited by the local lines company to do work on their network, which meant one less contractor for the Moores to deal with, says Jono, whose team also organised power supply to the green field site.

The hard work that went into the design and build of this shed is already paying dividends with the Moores able to take a step back from the day-to-day milking routine. The sophisticated Dairymaster milking system and labour-saving technology ensures that when the time is right, John and Jannine will be able to step back even further and appoint a sharemilker or contract milker, while they sit back and enjoy the fruits of their labour.

PH 07 578 0030

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Page 18

Coast & Country

Compatible

The side of the shed shows the two silt lines from the two big floods; 2004 is the top line and 2015 the bottom line.

Lois Natta

The lengthy yard was retained from the old dairy shed.

Pat McDonald from DeLaval, James MacDougall from MacDougalls and farm owner Michael O’Leary.

Michael and Lynette O’Leary are third-generation family owners of their farm at Whangaehu, about 15 minutes’ drive south of Whanganui.

Back in the day, Michael’s parents Humphrey and Joan farmed 40 acres and leased a further 200 acres, and his grandparents farmed 100 acres further down the valley.

The family is just reaching a milestone 100 years of farming in the valley, which is a huge achievement for a farming family.

They have been through two major floods from the Whangaehu River causing major damage to paddocks and fencing. “This farm,

along with many others in the valley, was hugely impacted by the floods,” says Michael. “We couldn’t use our pasture for six months as we lost all the pasture. During the 2004 floods the water ran under all the chiller units and motors.”

Michael indicated the silt lines on the side of his implement shed from both floods.

Bank on it He says when he was at school, the 33-year lease on the farm was up for renewal, but the banks would not lend the money to renew the lease. So between Michael and his brother Shaun, they went to another bank and got a

$90,000 loan which got them both started in their own farms.

Their goals were to have 1000 cows each in 10 years so that the partnership could be split and each farm would be financially viable.

That goal was reached in 2012.

When Michael’s dad retired the blocks were all in lots of 70 acres, so he and Lynette managed to purchase all the neighbouring farms over the years, bringing them to a total of 330 effective hectares. They now farm 820 mostly Friesian and Kiwicross cows.

The O’Leary families now own about onetenth of the cows in the Rangitikei district, which is definitely something to be proud of.

Whilst the original 60-bail herringbone – two

30-bail herringbones joined together – was cut back to around 15 bails and is now used for various animal handling jobs, the cleared space was utilised for the 60-bail rotary to be built over the remaining herringbone section ensuring it was able to slot into the existing rectangle yard.

The farm is managed by a contract milker, who in turn employs two labour units.

Biting the bullet Michael chose a DeLaval system for the simple reason that he has used MacDougalls for years and has found Brett MacDougall and his team to be a highly organised and well-run company.

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Page 19

AWAKERI

PH 07 578 0030

The DeLaval milking system.

The underpass leads into the centre of the platform.

James MacDougall explaining the DelPro interactive data display unit.

“We did delay calving by 10 days to give them a little extra time to complete the project,” says Michael. “And we are very happy with the new system. MacDougalls got it right from the start, they just bit the bullet and went for it.”

Michael says Pat McDonald, who is the lower North Island district sales manager for DeLaval, took him to visit a couple of farms “as we needed to make it a shed that would be compatible so that if the contract milker was not here, then I need to be able to look on my phone and see the job is being done right”.

Installed by MacDougalls from Pahiatua, the new DeLaval E100 60B rotary has all the new technology, including an inparlour feeding system.

Unique to the E100 is the DeLaval ComfortBail. This bail hides the wires, pipes and technology needed in the rotary milking platform, and integrates them into the bail. It also ensures clearer lines of visibility for milker and cow; easier, safer access for the milker, and a more consistent approach to the task of getting

cows on, milked and exited calmly and quickly.

The DeLaval Farm Monitoring Camera FMC60 provides safe supervision of the cows.

A portable and wireless receiver allows for constant supervision of the cows, allowing the milker to keep an eye on the exit area, backing gate and holding yard.

Automatic teat spray is sited on the platform with four individual spray nozzles providing accurate teat coverage just seconds after the clusters are removed.

Three feeds in one The DeLaval feed system was installed by Central Silo Systems, along with two 30 tonne meal silos supplied and installed by Central Silo

The cleaning corner, set up with DeLaval dairy hygiene.

Systems, has been set up to feed three different types of feed from the one dispenser.

The dispenser is designed with three internal lines and dispenses the correct amount of each type of feed to each individual cow to assist with sustaining and improving milking performance.

The silo can be filled with product by a blower truck with the addition of a pneumatic filling kit. “This system is more beneficial than using an auger,” says Central Silo Systems director Sean Currie. “It does not require the farmer to be present when loading the meal into the silos, and augers are limited in the reach they can obtain for the larger silos.”

The silos are constructed from heavy gauge G-90 galvanised steel with deep corrugation and a sturdy bracing system for the die-formed legs providing good structural support. The silos have a weathertight dieformed roof which has reinforcing ribs at the seams for added strength and ease of assembly.

The 22 inch diameter, warp-resistant top lid

closes tight to keep out moisture. Silo bolts have a built-in weather seal and a drip edge that keeps water away from the taper hopper and unloading boot.

Ultrafast milk evacuation The platform consists of a steel deck, has retention bars and automatic cup removers.

The high quality DeLaval MC53 milking clusters eliminate the risk of flooding and cross contamination and provides a stable vacuum under high volume milk flows of up to 15 litres per minute. The key to this ultrafast milk evacuation is the patented DeLaval TopFlow technology. Milk flows into the claw base and is extracted away, quickly and gently, through the unique centre-pipe. This keeps the claw clear from flooding and ensures vacuum stability, ensuring fast, smooth milk extraction throughout milking, while protecting milk quality.

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Coast & Country

Container pass constructed by Cody Cooper.

The Crozier refrigeration system.

Farm owner Michael O’Leary loves the solid steel walls and the rubber matting.

Central Silo Systems installed the two meal silos.

The bridge and a portion of the yard has been laid out with DeLaval interlocking matting.

Michael is so impressed with this, saying that he has “next to no foot issues” since installing this matting. “It takes all the stress and strain off the legs, and has reduced lameness by 90 per cent.”

Eventually he would like to install matting further out into the yard for added cow comfort. Constructed from high quality durable rubber, the interlocking pieces make assembly an easy task. The rubber matting has been designed with cow comfort in mind, with anti-slip and shock absorbency features.

MacDougalls purchased Croziers four years ago and have now incorporated dairy refrigeration into their company. Their team

installed a DeLaval double bank compliant water chiller, which uses food grade glycol.

The milk enters the vat at six degrees Celsius according to the new regulations.

Best sorting solution In day-to-day farming there are a number of reasons for separating a cow, which Michael has achieved by installing the DeLaval Sort Gate DSG3.

The DeLaval DSG3 sorting gates combined with the DelPro herd management system delivers Michael with the best possible solution for drafting his herd. This system allows sorting of the cows into their relevant group without interrupting the cow traffic. It also provides the herd with a stress-less way of drafting.

DeLaval’s single-lane drafting race.

The large rectangle yard is capable of holding 600 cows, and is equipped with power cannons to washdown after milkings.

Michael had seen a few sheep dairies and liked the idea of solid steel walls at the entrance to the bridge and decided to design a similar shed so the cows could see no humans as they come onto the platform. He found it excellent and stops the cows balking at the entryway.

“No cow ever stops any more, in fact we rarely need the backing gate at all now.”

The new shed has been equipped with an office-come-electrical room, a storage corner with dropdown vet platform and a washdown corner that is fully set-up with DeLaval dairy hygiene.

Earthworks were undertaken by Cody

Cooper from Excav8t Ltd Earthworks in Whanganui.

Cody and his team of two others re-did all the laneways, re-metaled the tracks and completed all the site prep for the shed. “A bit over 6000 cubes of soil was removed for the site prep,” says Cody. “It was definitely one of my bigger jobs.”

Using a shipping container lined with concrete blocks for stability and support, Cody utilised this as the underpass, which was set up through a hill. “This was an affordable solution to enable the herd to enter and exit the shed at the same time.” It was important that levels were right from all angles to ensure the structure did not collapse under the weight of the hill, says Cody.

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Page 21

PARISIENNE TRUST

Page 22

Robots

Coast & Country Aaron Kane and his DIY shed.

No.8 MacKenzie Dyer

Lely center manager Steve Bromley and farm owner Aaron Kane.

Following the track up to Aaron Kane’s Shannon farm leads to what looks like a moon base.

The bright, white structure is Aaron’s DIY container cowshed that houses something just as futuristic: The Lely Astronaut A5 milking robot.

Despite its new-age reputation, Lely Astronauts have been made and developed for 28 years, says Bromley Dairy and Pumps director and Lely center manager, Steve Bromley.

“Lely has been perfecting their milking robots for a long time, and the smart and refined technology of the A5 certainly shows it,” says Steve.

Aaron’s investment, paired with ‘number eight wire’ ingenuity, has transformed the way he operates his 92-cow organic jersey farm.

The Lely system Aaron has been milking with the Lely Astronaut A5 since December 2019. The cows walk themselves to the L5 – enticed by feed automatically provided to them while milking, having

The Lely Astronaut A5. pressure released from their full udders, and the fresh paddock of grass they go to once finished.

The cows’ Lely Qwes tags communicate with a transmitter, so the robot can recognise if the cow needs milking, as per the farmer’s settings.

Once the cow has finished milking, the Lely Grazeway automatically opens gate A or B, leading the cow to the opposite paddock they came from.

While Aaron operates an A and B Grazeway system, famers have the option of a third gate.

With no milking to do and no cows to round up, Aaron says he usually spends less than an hour in the shed a day. “I go there to hose down and that’s about it – the rest is taken care of.

“It gives me more time to tend to the rest of the farm.”

When it comes to milking, the Lely Astronaut A5 has everything covered. The robot provides a customised milking experience for each individual cow based on previous data it collects.

A 3D camera captures teat and udder positioning, allowing the cups to automatically attach; starting with the teat that takes the longest to milk.

Brushes clean the udders before each milking, encouraging the milk letdown response.

After milking, the brushes are disinfected, cups are rinsed with water, and teats are sprayed with care product, eliminating the opportunity for transmission of bacteria. Different machine

Lely Qwes tags. wash cycles can also be programmed.

While being milked, the cow stands on a scale. Their weight and other health information instructs the robot on how much feed the cow should receive.

Each milking takes about six minutes. Once finished, the Grazeway system opens the gate.

“It was amazing how quickly the cows adapted,” says Aaron. “By day two, they were away.”

Happy cows It’s impossible not to notice the calm demeanor of Aaron’s cows. When taking photographs of their Qwes tags, there wasn’t any skittishness – they happily approached a stranger with a big, loud camera.

“My cows were quiet before, but now they’re on another level because they’re so relaxed,” says Aaron.

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Page 23

PARISIENNE TRUST

Quarry stones for the tanker track supplied by Shannon Bulk.

The Lely Grazeway selection box and Lely Luna cow brush.

Accessible cables make for easy maintenance.

Aaron uses the T4C management system on his computer and phone.

The milking parlour.

Steve says seeing stress-free cows is consistent on every Lely Astronaut farm he’s visited, because the system is made to work with their natural behaviour. “They live by their own schedule, which transforms their entire demeanour.”

With the goal of incentivising the cows as much as possible, Aaron built his own shed closer to the cows’ paddocks, rather than gutting out his herringbone shed that’s much further down the 45ha farm.

For the work he didn’t complete himself, Aaron turned to trusted local businesses who he’s worked with before.

Shannon Bulk Haulage Ltd provided the quarry rock for a new 500m tanker track to the ‘moon base’, which created a new access point from the road onto the farm.

Shannon Bulk Haulage Ltd owner Janelle Gattsche says quarry rock is an incredibly

The container dairy. durable option for a dairy track.

As well as quarry rock delivery, Shannon Bulk’s services include excavation, grading, and rolling. “We can help with a wide variety of farm projects,” says Janelle. “We are family owned and operated, local, and have been in the business for more than 50 years.”

Paul Ireland Digger Hire are a Levin-based business, which Aaron has also used before.

“We were part of the overall project, delivering metal and sand supplies as Aaron needed it,” says Paul Ireland Digger Hire’s director Daniel Ireland.

Container cowshed Aaron’s cowshed is made out of shipping containers, with a metal frame and tarp for a roof. It took him a few months total to make.

“I was worried that it might get too hot inside, but that hasn’t been an issue,” says Aaron. “It

Steve Bromley and Aaron Kane inside Aaron’s DIY dairy shed. does the trick of keeping the cows, and the robot, dry.”

On each side of the tarp-barn is a container, one for the dairy, and another for a computer room, where Aaron can access Lely’s T4C management system. More than 1200 reports on the herd’s health are available through Lely’s T4C system that Aaron can access on his phone and computer.

If there’s an issue, the system alerts Aaron.

“Two of the greatest indicators of a cow’s health are milk and rumination,” says Steve.

“The milk is continually tested through the robot, and rumination behaviour is tracked through the Qwes tags – so issues can be addressed early.”

Aaron says farmers shouldn’t be intimidated by the technology. “It tells you information that can’t be seen with the human eye that can save a cow’s life.

“The system is user-friendly, and if I ever have a question, a Lely technician is available 24/7.”

Milking robots have a reputation for being $1million each, which Steve says isn’t necessarily the case.

Half the price Aaron completed the entire project, earthworks and all, for about half that. While having just one Lely Astronaut works perfectly with Aaron’s farm, Steve says it can be adapted to suit any situation “It’s a modular design. The setup is where the costs are, and from there it’s easy to add robots on.”

Aaron says the A5’s running costs are also less than he expected. He has no regrets.

“I couldn’t be happier with my decision to buy the A5,” says Aaron. “It’s the cheapest farm worker I’ve ever had.”

Lely Astronaut A5 milking robot

The new milestone in milking

BARKER FARMS

Page 24

Rare

Coast & Country

design Steve Edwards

Kelvin Barker in front of his new dairy shed at Maramarua.

Clean lines are a feature of the Barker shed at Maramarua.

A rare “open plan” design has been used for a new farm dairy at Maramarua. Kelvin Barker says he built the shed on McWatt Road with both staff and cow comfort in mind.

At three metres the pit is double the usual width, while the shed itself is 16m wide.

In a move away from the traditional herringbone design, cows are side-by-side in roomy bails with a wide exit area.

More space “There is no congestion,” says Kelvin, who owns the property with his wife Faye. “With more space the cows are more comfortable.”

Kelvin says the 20-aside design has attracted a lot of interest in the farming community. With staff having extra space, “it is nice to milk in”. “There is also no pressure on cows entering and exiting the milking area.” Two staff can milk the 420-cow

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When looking at shed designs, Kelvin says he couldn’t justify the cost of a rotary. He saw an example of the design he ultimately pursued on a farm near Cambridge and was “quite taken by it”.

“There is excellent cow flow,” says Kelvin. “And, it’s good for staff.”

The design also features a high roof, making for cooler conditions for both staff and cows through summer.

In something of a family affair Kelvin engaged the services of his brother Wayne Barker from Ngatea Milking Machine & Pump Services and another brother Steve Barker, who heads Steve Barker Earthworks, for the project.

Kelvin and Faye have been farming on McWatt Rd for 30 years, starting with a neighbouring 70ha block. Ten years ago they bought a further 110ha, where the new shed is now, milking two herds.

There was a cowshed on each property, a 16-aside herringbone on the smaller farm and a 24-aside herringbone on the larger

The extrawide pit.

property. “They were both very old sheds,” says Kelvin.

A feed pad was built on the larger farm four years ago, and an effluent pond the

following year.

Kelvin says he started thinking about a new shed two years prior to construction in 2019. The shed is on a new site, which Kelvin says is more central on the farm. “It’s more accessible to races.”

Building started in March 2019, with the first milking in October that year.

Identifying cows individually The Barker shed was designed by Morrinsville-based Chapman Dairy and constructed by Don Chapman Waikato.

Chapman Dairy head Don Chapman says the concept was to make the milking area “free flow” for milking cows, with a wide pit for staff comfort and movement. “It is roomy, light and airy,” says Don.

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The Race Works Wrangler.

The chiller and vat units installed

by Ngatea Milking Machine & Pump Services.

Refrigeration units provided by DeLaval.

Automatic cup removers, courtesy of DeLaval.

An open plan design is a feature of the Barker shed.

This is just the third or fourth such design Don has been involved with during his long tenure in the business. “You follow the client’s request,” says Don. “It’s pretty much on a case-by-case basis.”

The design adopted by the Barkers is not as rigid as traditional “batch milking”, says Don, allowing greater flexibility for slow milkers. “You can identify cows individually.”

The balance of the Barker shed design was “pretty standard,” says Don. Don Chapman Waikato director Shanan White says this was the third such “rapid exit” shed he had been involved with. He understands there are just six to eight like it in the country.

“It’s not really a herringbone or a rotary.” Shanan says two staff were on-site for about 18 weeks.

The site was prepared by Steve Barker Earthworks from nearby Ngatea. Steve says he undertook all earthworks for the shed and yard.

Being “half again wider” than a traditional herringbone shed that size, and with a rectangular yard, Steve says the project was quite unique.

His team also dug the 40m by 40m by 3.3m effluent pond, while the feed pad was created four years earlier. Material was used as topsoil on-site, with metal brought in from a local quarry.

Page 25

BARKER FARMS

The yard had been pre-loaded with metal 12 months before construction began.

Using a smaller digger, Steve Barker Earthworks also dug trenches required for water and electricity systems associated with the shed.

Parallel parlour The milking plant features automatic cup removers and teatspraying, along with an auto washdown system, supplied by DeLaval and installed by Ngatea Milking Machine & Pump Services.

Wayne Barker, from Ngatea Milking Machines & Pump Services, says this shed set-up was quite a challenge as it was the first one of these systems he’s been involved in.

But, with the support from the technical team from DeLaval, Wayne says the project went very well.

DeLaval district sales manager Malcolm Kensington says the Barkers had been looking at a new milking plant as the existing one was too small.

“They were looking at a rotary until Wayne showed them the DeLaval P2100 Parallel Parlour milking system in Cambridge,” says Malcolm.

“Kelvin was quite taken by the ease of milking in it and the

reports that the Delpro herd management system would give him about his cows, as they have contract milkers.”

Malcolm says the DeLaval P2100 Parallel Parlour that the Barkers chose has stainless steel cabinets with incorporated milk recording, cow ID and drafting system.

“The cows enter the same way as normal, but every cow is separated by an index gate and they exit out the front – where the breast rail lifts up – rather than walking the full distance of the pit area, therefore faster cow trafficking.”

Hoof care Malcolm says it is a low line milking system that has two lots of 20 clusters with two 100mm milk lines and is washed with the Trombone washing system connected to the automatic washing system, which guarantees the plant is washed the same way every time.

Kelvin and Faye also opted for the Race Works Wrangler for hassle-free hoof care of their herd.

The galvanised iron cattle crush, supplied by Whakatane-based The Wrangler, provides “total safety for the cow and the farmer,” says founders Wilco and Waverley Klein Ovink.

Waverley says The Works unit features a walk-through headbail, leg winches and front foot supports.

Page 26

FINLAYSON

Coast & Country

old

New Steve Edwards

A bird’s eye view of the DeLaval rotary platform on the Finlayson farm.

A marriage of old and new has cut milking time in half at a dairy farm near Port Waikato.

Bryce Finlayson says using existing infrastructure as part of a new dairy shed complex on Frost Road had obvious financial advantages, while also not interfering with his year-round milking routine.

His herd is split into two – 150 and 400 cows – for winter milking, calving in March and July. The cows are milked together through spring.

Earthworks for the new 50-bail rotary began in August 2019, while the existing 36-aside herringbone remained in action.

“With winter milking you don’t stop,” says Bryce. “We had to keep the old one going.”

Building on an adjoining site also meant use of an existing effluent pond, and electricity and water supplies. Similarly, the same race system and tanker track remain in use.

The property, which Finlayson Farms has owned since 1992, has 200ha in dairying and 100ha of wetlands.

Bryce says a decision to build a new dairy was made in 2019 to cater for up to 600 cows and reduce staff time in the shed.

Milking time cut Milking time has been cut from three-and-ahalf hours to 90 minutes, with just one person required for milking duties and another doing stock/yard work on a rotational basis night and morning.

Previously, three staff were needed for every milking. “We’re pumping along,” says Bryce.

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The old and new yards were “married” together, with a “step down” to the milking platform required to tie in with the existing yard level.

Builders from Don Chapman Waikato came on-site in September 2019, with the shed designed by Chapman Dairy.

Bryce adopted a “halfway house” approach towards automation, with teat-sprayers, cupremovers and an air purge plant cleaning system.

The yard is hosed down in the traditional method, with effluent gravity fed into the existing pond.

This pond was built by Agruline, based at nearby Onewhero, four years ago.

After Bryce completed the required earthworks himself, Agruline owner Karl Hogan said three-four staff completed the 40m by 30m by 4m pond in two-three days.

This included supply and installation of the associated liner.

The Finlayson shed was designed by Morrinsville-based Chapman Dairy, who met on-site with Bryce in mid-2019.

New experience The vastly experienced Don Chapman says he’d never had a project quite like that one, marrying an existing herringbone shed to a new rotary.

“But it was the only real place to build the rotary,” says Don. “It was all about getting the levels right.”

Don says putting in a milking pit around the platform saved on excavation costs, while the existing drafting area could also be re-used. “It makes the best of what’s there,” says Don. “But, there were no compromises.”

Page 27

FINLAYSON

PH 07 578 0030

A view from above of the new shed and the nearby existing effluent pond, completed by Agruline, which now services the new shed.

The Protrack drafting system courtesy of LIC Automation.

The shed was built by Morrinsville-based Don Chapman Waikato. Director Shanan White says marrying the old with the new was an “odd one.” “It was a tricky site, with the contour of the old shed.”

Shanan says a milking pit was required around the rotary platform, otherwise the whole shed would have needed to have been “dropped 600mm”.

One of the first on-site for construction was Pump & Electrical Services. Huntly branch manager Grant Thompson’s team started work on ducting for electrical cables in November 2019.

“These were created under the concrete in the milking area before the platform was installed.”

Grant says control boxes were mounted under the platform – one per bail – for automatic teat-spray and cup removal systems, as well as

Bryce Finlayson at his new dairy shed.

retention arms and in-shed feed (meal).

Because of the lay of the land and to fit in with the existing yard, a step down to the milking platform was required in the design instead of the traditional flat entrance.

Pipework was modified to suit what was Grant’s “first install of this type”.

This featured a main washdown water line positioned 2.5m off the ground around the milking platform. New switchboards were required, which Grant and his team fitted in a separate room on-site.

Hot water system Pump & Electrical Services also installed the hot water system, including two 500L tanks, vacuum pumps for the milking plant, secondary plate coolers, an 11kW washdown pump, an

air compressor for the teat-spray unit and an air purge system to flush the milk lines – which is used twice during each cleaning cycle.

The milking plant is a 50-bail DeLaval Rotary E100 with automatic cluster removers and an on-deck teat spray system.

DeLaval district sales manager Malcolm Kensington says the plant has a Lobe vacuum pump system with a variable speed drive which reduces wear and tear on the vacuum pump, offering a power saving of up to 70 per cent.

“The milking system has a 100mm loop line, washed with the DeLaval Trombone wash system.”

Malcolm says the milk transport system has a 2.2kw milk pump with a variable speed control drive to optimise milk flow and milk cooling.

“The milk filter will cater for up to 880 cows

and the plate heat exchangers are the industrial type, with one used from the existing plant.”

Malcolm says the teat spray system is incorporated with the cluster removers so as soon as clusters are removed the cow is teatsprayed rather than the cow waiting to exit before this happens.

Blending old with new was also the focus for work undertaken by LIC Automation.

Perfect timing LIC product marketing manager Teresa Karl says Bryce had Protrack Vector in his old shed and decided to move his draft gate to the new facility.

“And the timing was perfect for migrating to the new Protrack modules, especially now since he could choose what he wanted to have.”

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FINLAYSON

Page 28

WRS Refrigeration director Mike Barnett completed vat chilling and dairy refrigeration work on the Finlayson farm.

SealesWinslow animal nutrition TSR – Waikato – Spencer Hickford.

Pump & Electrical Services’ Huntly branch manager Grant Thompson in front of hot water cylinders at the Finlayson farm.

The existing effluent pond, completed

by Agruline, now services the new shed.

So not only did Bryce migrate his old Vector system to the Protrack Hub, Draft, and Animal modules, he also upgraded to Protrack Rotary ID. Teresa says he still has the same functionality his gate had before, but the hardware of his system has been updated to allow the new software to run, with the added advantage of being able to draft directly from MINDA LIVE, through the Protrack Animal module.

This module also allows him to record events in real time, with no double entry into MINDA LIVE. “The upgrade to Protrack Rotary ID allows in-bail identification of animals, coupled with our audio, and visual alerts on the milking screen, help Bryce to identify easily and quickly any cows of interest and ensure they are taken care of as quickly as possible,” says Teresa.

Refrigeration work was undertaken by Waiuku-based WRS Refrigeration. Company

Coast & Country

director Mike Barnett says this included a vat chiller and dairy refrigeration unit, and installing a water chiller. Mike says water is used in pre-cooling of milk to the desired sixeight degrees Celsius. “The four refrigeration units are connected to nearby water tanks and can cater for any increased herd size in future.”

Bryce decided to go with a PPP Industries’ feed dispenser and auger line system with a 1205 silo.

Precise feeding PPP dairy sales representative James Kellow says the silo has a 58m3 capacity and a 60 degree base, holding 36-42 tonnes of feed.

“With a feed dispenser and auger line system, you can alter feed dispensing times to change how much each cow is getting.

“This means the Industrial DC motor is turned on and off for a pre-set amount of time for each bail.

The DeLaval Rotary E100 ComfortBail with retention straps and on-deck teat spray and the exit area, which highlights how easy it is for the cow to exit with the low profile bail.

“The system has an empty bail sensor so it won’t feed empty bails,” says James. “It also has a second sensor to detect if cows are going around a second time, therefore not feeding them.”

James says this system also has the ability to recognise if the platform has been reversed so the control box won’t double feed cows.

“The controller also has the option for different feed quantities in a herd A and herd B setting.”

James says the reason the feed dispenser and auger line system is more precise is because with other systems on the market you get variances with the amount of feed in the auger.

The meal used in this system is supplied by SealesWinslow at Morrinsville. SealesWinslow’s Waikato animal nutrition technical sales representative Spencer Hickford says 24 tonnes of meal was initially supplied to Bryce Finlayson after consultation in October 2019.

“We got to understand his needs, relating to

The pumps just made for a high-fibre diet.

the herd size and pasture type.”

Each cow gets 1.3kg of meal daily, which Spencer says is a high protein recipe with three types of starch – maize, wheat and barley. “A sweetener, akin to candy floss, is added to make a tasty treat for the milking cows.”

Trenching Spencer says other minerals such as zinc and magnesium can be added to the mix as required later in the season.

Huntly-based Broughton Contracting carried out earthworks relating to the placement of the rotary platform. Owner/operator Tim Broughton says two staff excavated the area inside the shed building which had previously been erected. “We dug it out and took away the material,” says Tim. The company also provided trenching services later in the project to cater for underground utilities.

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Page 29

FINLAYSON

PH 07 578 0030

POLYTHENE PIPE FITTINGS AGRICULTURE | HORTICULTURE | INDUSTRIAL | IRRIGATION | HYDROPONIC A

A

B

A

B B

AB BEND 1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

15mm 20mm 25mm 32mm 40mm 50mm

A

AMB MALE BEND

ARFB REDUCING FEMALE BEND 15 x 20mm 20 x 15mm 25 x 20mm 20 x 25mm 32 x 25mm 40 x 32mm 50 x 40mm

1/2” x 3/4” 3/4” x 1/2” 1” x 3/4” 3/4” x 1” 1 1/4” x 1” 1 1/2” x 1 1/4” 2” x 1 1/2”

ABE BRACKET ELBOW

15mm 20mm 25mm 32mm 40mm 50mm

1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

15mm 15 x 20mm 20mm 20 x 15mm 20 x 25mm

AU UNION 1/2” 1/2” x 3/4” 3/4” 3/4” x 1/2” 3/4” x 1”

20 x 20mm 25 x 25mm 32 x 32mm

3/4” x 3/4” 1” x 1” 1 1/4” x 1 1/4”

B

B

ARFC REDUCING FEMALE COUPLING

ARMB REDUCING MALE BEND

20 x 15mm 25 x 20mm 32 x 25mm 40 x 32mm 50 x 40mm

15 x 20mm 20 x 15mm 20 x 25mm 25 x 20mm

3/4” x 1/2” 1” x 3/4” 1 1/4” x 1” 1 1/2” x 1 1/4” 2” x 1 1/2”

AMBL MALE BEND (LONG) 1/2” x 3/4” 3/4” x 1/2” 3/4” x 1” 1” x 3/4”

15mm 20mm 25mm

AFB FEMALE BEND 1/2” 3/4” 1”

15mm 20mm 25mm 32mm 40mm 50mm

1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

ASCL STRAIGHT COUPLING (LONG) 15mm 20mm 25mm

1/2” 3/4” 1”

A B

A

B

ARMC REDUCING MALE COUPLING 15 x 20mm 20 x 15mm 20 x 25mm 25 x 15mm 25 x 20mm 32 x 20mm 32 x 25mm

ARMBL REDUCING MALE BEND (LONG) 1/2” x 3/4” 3/4” x 1/2” 3/4” x 1” 1” x 1/2” 1” x 3/4” 1 1/4” x 3/4” 1 1/4” x 1”

15 x 20mm 20 x 15mm 20 x 25mm 25 x 20mm

AMC MALE COUPLING 1/2” x 3/4” 3/4” x 1/2” 3/4” x 1” 1” x 3/4”

15mm 20mm 25mm 32mm 40mm 50mm

1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

A A

15mm 20mm 25mm 32mm 40mm 50mm

ASC STRAIGHT COUPLING 1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

15mm 20mm 25mm 32mm 40mm 50mm

1/2” 3/4” 1” 1 1/4” 1 1/2” 2”

A

B

B

ARC REDUCING COUPLING

ART REDUCING TEE

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Page 30

TOTMAN DAIRIES

Refit for

Coast & Country

Steve Edwards

A Waikato dairy farmer has his ‘dream dairy’. Aaron Olesen manages a 200-hectare property on Totman Rd near Matamata.

While the building and yard structures were sound, Aaron says the 40-bail rotary was becoming a liability and a refit was due.

Continual problems with the original cup removers meant that a decision was made to change to manual cup removal in 2016.

Manual cup removal was less efficient for staff with two people required for milking but with 600 cows, it was acceptable.

After scoping the project, the decision was made to upgrade the existing 40-bail rotary to improve efficiency and provide the benefits of 2020 technology.

Staff saver Aaron says that various improvements have allowed the operation to grow, now milking 740 cows, which requires just one person in the dairy – allowing flexibility for time off and

The new bails, including automatic cup removers and teat-spray system. other on-farm work.

The retrofit, with updated automation including automatic cup removers, automatic teat spray, vat wash and plant wash, was approved in early-2019.

Aaron says the upgrade was limited to areas that made a difference. The existing milk tanks and building structures – including the plant room, vat stand and office – remain unchanged.

The operation now has elements of LIC Automation’s Protrack suite: Protrack Draft and Protrack ID Rotary, which includes Protrack Animal.

The Protrack Draft gate, supplied by LIC Automation and installed by Shane’s Mobile Maintenance, was included in the revamp.

Protrack ID with Protrack Animal enables in-bail identification for each animal with direct integration to LIC MINDA LIVE.

Aaron Olesen has his dream shed in the Waikato and with the Protrack drafting system in-shed monitor. (Right)

LIC Automation solution manager Darcy Oates says this technology allows anyone milking to see information relating to that animal including alerts – both audio and visual – for treatment cows or management traits.

“Events can be added to each individual animal via a smart device – like a cellphone, tablet or computer – and they are sent directly to the MINDA LIVE holding pen to await approval,” says Darcy.

Information on hand “The operator’s smart device can be set up to show information that you need to see according to the time of season, so all information is at hand when required,” says Darcy.

The Protrack Draft gate can be controlled via an app on the chosen smart device or on the milking software at the dairy, which runs the

Protrack ID Rotary as well.

LIC Automation national sales and product manager Jason Quertier says the app can be used anywhere on-farm. “Once you come back to the shed, the drafts download automatically to your Protrack software,” says Jason. “Drafts can be scheduled for the future or at next appearance at the gate,” says Jason.

Aaron can also use simple reports to see if animals were missing from milking, which animals were drafted and why, and what treatments were given at a milking session.

The yard was re-designed to improve cow flow and cleaning efficiency, with new backing gates rotating 360 degrees – instead of 180 degrees – with an associated yardwash system installed by Shane’s Mobile Maintenance.

Director Shane Williamson says a key feature is the backing gate and yardwash, slung under the gate, is controlled by milking staff in-shed.

PH 07 578 0030

Page 31

TOTMAN DAIRIES Qubik Putaruru branch manager Andrew Linehan.

Moa Rotary Platforms’ Waikato manager Shane Arthur.

Waikato Milking Systems’ general manager sales and operations Craig Lowry.

Farm manager Aaron Olesen, right, with his 2IC Liam Loomans on left.

“We wanted to keep it simple and not overcomplicate things,” says Aaron.

Just one new piece of yard was added, to accommodate the Protrack gate and area to draft to.

Meanwhile, updating technology in-shed was headed by Waikato Milking Systems. “We started with a blank canvas,” says Waikato Milking Systems’ general manager sales and operations Craig Lowry. “The only thing that stayed in the cow bail area was the steel platform.”

“The ageing platform was past its use-by date,” says Craig. “If you liken it to an old car, we just kept the chassis.” The goal was to add modern equipment and technology and breathe new life into the dairy shed – to deliver reliability and efficiency for the farm’s current milking conditions, while providing the ability to upgrade to higher levels of technology in the future.

“It was determined that the deck and running gear under the platform were in good condition – so they were retained as-is to reduce the overall cost of the refit.”

Craig says new automation-ready Waikato Milking Systems’ standard stall work and deck ports were fitted, and a new Waikato Milking Systems’ milking plant was customfitted to the existing platform sub-structure, underneath the deck.

Cow comfort “Rubber mats were fitted to the existing stainless-steel platform to improve aspects of cow comfort, with the reduced noise they settled more quickly.”

Craig says the SmartSPRAY in-bail teat spray system, supplied by Waikato Milking Systems, ensures the correct timing and placement of teat spray at every milking.

Installation of the new equipment and systems was undertaken by Qubik.

The Protrack drafting gate.

Qubik’s Putaruru branch manager Andrew Linehan says this included platform mats, SmartSPRAY system in each bail, ECR-5 cup removers and bail gates.

In the plant room, Qubik put in the vacuum system, a BP400 blower and drive, plus an 8000-litre double-bank plate cooler and stand, plus the automatic milk plant and vat wash.

Structural work on the milking area was undertaken by Matamata-based Moa Rotary Platforms.

Moa’s Waikato manager Shane Arthur says all existing bails were removed and updated, including retention arms and kick rails.

“We also cut holes in the milking deck to adapt it for the introduction of new automatic cup removers,” says Shane, who reckons four staff worked on the project for about two weeks.

Wide scope Laser Electrical Putaruru was commissioned to undertake the full electrical installation

and was given wide electrical scope – which included full automation for the cowshed plant and vat-wash.

Director Chris McKillop says automation was achieved using a Programmable Logic Controller (PLC) and Human Machine Interface (HMI) screen for the general running and control of the cowshed equipment.

“This was expanded to wireless control and monitoring of the effluent and water system.”

Chris says with automation comes the ability to remote access to the farmer’s PLC if internet WiFi is available – “so if any technical issues arise they can be diagnosed online and assist farmers remotely if required”. Other work carried out was improvement of lighting using LED lights.

Chris says the cowshed has also been set up with a generator connection to give surety of power “so the everyday operation is not affected, particularly the water supply and milk refrigeration”.

Qubik are proud to have supplied and installed the milking machine for Totman Dairies.

Page 32

BROWNE PASTORAL

Spectacular sheep

shed

Mention the Browne family from Cambridge and most will associate it with horses – racing and polo.

But you can add sheep – sheep milking to be precise – to the family CV. Allan and Toni Browne have ventured into sheep milking in a big way on the family’s Redoubt Road property, building a 70-bail rotary for their 1300 ewes.

The Browne family has a history in the area dating back six generations to 1888 – Allan is part of the fourth generation – with his greatgrandfather originally establishing a sheep and beef operation on what is known as Lanherne.

Allan is a past NZ representative polo player and current vice-president of the NZ Polo Association.

His father was renowned jumps jockey

Steve Edwards

Allan Browne at the control panel. and beef unit. However, in 2018 Allan became interested in the concept of sheep milking.

He knew nothing about the business until attending an Open Day run by Maui Milk. “It just snowballed from there.”

Ken Browne, who also later became a highly successful owner/trainer with his wife Ann. In 1991 Ken received an MBE for Services to Horse Racing. Involved in the industry for more than 40 years, he passed away in 2006.

Family affair Allan is a shareholder in a family company, which now owns the Redoubt Rd operation, running sheep, beef and racehorses. In keeping with family tradition, staff on the farm includes Allan’s daughter Estee.

The milking ewes, plus 450 replacements, are run on a 570ha block. Allan supplies Maui Milk, based at Innovation Park in Hamilton.

His flock is Maui Milk’s own breed of dairy sheep – Southern Cross – a hardy ewe suitable for New Zealand’s conditions.

The property had been a traditional sheep

Coast & Country

Collecting info Visiting a number of sheep and goat milking parlours around the country, Allan gleaned information and advice. Considering the land space and flock size, a decision was made to build a 70-bail commercial sheep milking operation. The greenfield site was developed using existing holding yards and a loading race linked to the new milking shed.

Allan says they were also able to tap into existing water and electricity supplies, with the on-site transformer upgraded to power the new shed.

About 2m of soft topsoil was removed by

Lame cows and bulls Preventa�ve trimming Heifer teatsealing Bulls - Preventa�ve blocking Hoof knife sharpening Available North Island wide

Curin Contractors, from nearby Roto-o-rangi, for the formation of the pad.

Company coordinator Shane Pelling says the soil – “good clay” – was used on other parts of the farm. Curin Contractors also undertook raceworks leading into the shed and development of the tanker loop. “The site was dug out, including the pit, in February,” says Shane.

A team of five-six staff were on-site for about a month. The raceworks material is a mixture of brown rock and ground rock covered with soft rock for cow comfort. Shane organised getting diggers, trucks and products on-site, working closely with builder Shanan White from Don Chapman Waikato.

Page 33

BROWNE PASTORAL

PH 07 578 0030

Waikato Milking Systems’ general manager sales and operations, Craig Lowry.

Don Chapman, left, and Shanan White.

Phase Electrical director Liam Carter with the yard video monitor.

Corohawk managing director Chris Hawkings.

Allan has been a loyal customer of Curin Contractors for more than 15 years. “He is great to deal with,” says Shane. “Nothing is ever a problem.”

First platform The technical side of the Browne project was overseen by Waikato Milking Systems’ head of sheep and goat milking, Andy Geissmann.

As a world-leader in rotary platform technology, the company’s first internal sheep platform presented a challenge for the traditional bovine-focused company, says Andy.

However using their significant technical experience in internal platforms, Andy says they were able to transfer their expertise to this small ruminant system. “We had undertaken a number of smaller herringbone sheep parlours in the past, but with small ruminant milking gaining traction in the NZ market, this is a growing segment that Waikato Milking Systems

Qubik representatives Jeremy Collett, Nick Heffer and Kyle Osborne.

Allan Browne with his daughter Estee and fellow lamb-rearing staff member Susan Wiltshire.

is keen to be a part of.”

Sheep have unique behaviour patterns, so the system was configured to ensure the sheep were always moving forwards, which reduces their stress levels, says Andy.

These factors were key in the design and integration between milking platform and the shed undertaken by Chapman Dairy. “There has to be a flow into and off the milking platform,” says Andy. “The sheep also need to see where they are going. You have to give them a view.”

The internal rotary allows the operators to be closer to the animals, and to see and hear everything that is happening – meaning you can respond to any problems faster.

With consistent sheep flow being a nonnegotiable, the yard-to-platform flow was

achieved through a reducing lead-in and ‘turn-style’ load into each bail.

Andy says an automatic feeding system is key, as the individual feed allocation entices the sheep into the bail, triggering a ‘head-lock’ so they are ready for milking.

Waikato Milking Systems provided automatic cup removers and auto wash equipment. The milking system is specifically designed for sheep, says Andy. “It’s more gentle in milk processing.”

Refrigeration and washdown systems are similar to those used in dairy sheds.

Made to measure Designer Don Chapman, also tackling his first ever rotary sheep parlour, says the key difference from a traditional dairy shed was the

“orientation” of the sheep on the platform. “It was tailored to suit,” says Don. There are no railed single bails, as in a dairy rotary, with the sheep lining up beside each other and held in a “head-lock” while being milked from inside the pit.

This required the inclusion of a pedestrian underpass, built by Don Chapman Waikato, from outside the platform into the pit.

Don says the associated buildings – plant and pump room – were based on the same principle as a dairy parlour but sized to suit the sheep milking operation.

Don Chapman Waikato director Shanan White says the company had two-three staff on-site for 15-16 weeks.

SPECIALISED COATINGS LTD

BROWNE PASTORAL

Page 34

The milking plant from inside the platform.

The rotary platform and bridge at right.

Changes from the traditional dairy rotary included a covered yard – protecting the sheep from the elements. “Sheep feel the heat,” says Allan. “The shelter allows them to cool down before milking.”

Shanan says another difference was the inclusion of black screens on rails around the yard and on the entry bridge. “This helps with the flow and behaviour of the sheep,” says Allan. “They can’t see out and get distracted, so just follow the leader.”

Shanan says this also meant less rails, and lighter material, were used in the project than in a dairy cow rotary.

Traditional design The building is 14.5m wide by 30m long, with the circular yard laid in the traditional fashion. Sheep are guided on to the bridge from the yard by a 360-degree backing gate.

Don Chapman Waikato also built the associated plant and milk rooms. Sheep milking

plant and water reticulation installation was undertaken by Qubik.

Small ruminant sales specialist Nick Heffer says Qubik started the planning process with Allan and Toni before the annual National Fieldays at Mystery Creek in 2019.

“The idea was to create a user-friendly milking shed, which would enable fast, efficient milking and allow staff to spend more time with the sheep and on daily farm jobs.”

Through consultation with Waikato Milking Systems and Qubik, Nick says the plan was set to build and install a 70-bail internal rotary shed that would include cup removers and a state-of-the-art stainless steel platform.

“With more than 30 years’ hands-on experience, Qubik was happy to work with Allan and Toni on the milking machine consultation and assist with all milking options and all the water reticulation in and outside of the shed,” says Nick.

Qubik installed the Waikato Milking Systems’

Coast & Country

Sheep are enticed into the bails with an individual feed system.

Moa Rotary Platforms’ service technician Matt Kekesi. internal 70-bail rotary plant, which also includes automatic cup removers and state-ofthe art rotary gland. Plus, Qubik installed an automatic plant-wash system and automatic vat wash system.

“At a push of a button this allows the milkers to focus on other areas of the farming system, knowing that a complete wash cycle is carried out on the milking plant efficiently and effectively,” says Nick.

Water works Qubik also installed the new water reticulation system in the shed and outside for the internal 70-bail rotary milking shed, says Kyle Osborne, water and effluent specialist for Qubik.

In the shed Qubik installed a new 11kW Lowara variable speed washdown pump with a Hydrovar VSD and pressure tank. “A new stainless steel Waikato Milking Systems’ double

bank plate cooler is supplied water via a new 2.2kW Lowara water pump and pressure tank.”

Kyle says Qubik supplied two 450 litre hotwater cylinders, with a double heater stand, above a stainless steel wash tub.

“The shed water uses a 76mm ring main, allowing Allan multiple washdown points inside and outside of the dairy shed.”

Qubik also provided two automatic vat washers, plus a variable speed blower vacuum pump and a variable speed milk pump.

SmartPULS pulsators are used, along with ECR5 cup removers.

Jeremy Collett, the milking machine specialist for Qubik, says the company was part of a site meeting in November 2019, with the bulk of the work undertaken in March 2020, before the Covid lockdown. This was the company’s first ever sheep parlour, with six to eight staff involved in the project.

Page 35

BROWNE PASTORAL

PH 07 578 0030

The vacuum pump and associated equipment.

The plate cooler.

The shed water system in the plant room.

The milk vats and refrigeration unit.

Matamata-based Moa Rotary Platforms also broke new ground in engineering the heart of a sheep milking shed. Service technician Matt Kekesi says the company had previous experience in goat parlours. At the Browne property, Moa “put it all together”. This included building the 70-bail rotary platform on-site.

The company also installed the bridge from the yard to the platform, plus rails and bails.

“Usually, such a project involves a lot more welding, but the Browne shed used structures bolted in sections.”

Moa had a full-time staff member and a parttimer on-site for eight-nine days.

Powered-up The Browne shed was also the first of its type undertaken by Te Awamutu-based Phase Electrical. “We have done several herringbones

Hot water cylinders in the plant room.

Milking time at Browne Pastoral.

for sheep milking,” says director Liam Carter.

Following a site meeting, Liam says first up was an upgrade of the electricity transformer servicing the shed. “Mains cables were laid and ducting installed prior to the concrete floor being poured.”

As the building progressed, Liam and his team wired up the associated pumps, plant and lighting, along with a camera and screen used to monitor the yard.

Allan says staff cannot see all of the yard from the pit – so the monitor identifies that sheep are moving comfortably with the backing gate.

Ohaupo-based Corohawk worked with Waikato Milking Systems to deliver the feed system. Feed from a 16-tonne silo is delivered to units at the head of each bail on the milking platform.

Corohawk managing director Chris Hawkings

says the feed is pushed through a PVC pipe to the individual troughs via an auger powered by a 0.75kW motor.

A measured amount of maize – 300g per sheep per milking during full milk production – is dispensed automatically as the milking platform rotates. It is then re-filled for the next rotation.

Chris says this is a cost-effective feeding method. “The system allows you to control feed delivery to the sheep with precision, without any waste of food. It also helps entice the sheep onto the milking platform.”

Chris says Chore-Time technology is used, based on systems adopted successfully by the commercial chicken industry.

The milking parlour was given a test run in June with 40 cull ewes from Maui Milk. “It

went way better than expected,” says Allan.

To get his sheep used to the new surroundings, Allan put them through the bails without milking them in early-August.

The first pick-up of milk from his own flock was on August 28. Allan plans to milk his sheep in three or four mobs of about 300 head apiece, one after the other. Two staff will man the pit, with another bringing the sheep in to milk.

Allan says an internal rotary lends itself to fewer staff. “You have a wider and better view of the sheep being milked from the pit.”

The 1300 ewes can be milked in two-and-half hours. And Allan says expected production is 150 litres-200 litres of milk per animal during the six-month season from August-February.

The milk is processed into infant formula by Maui Milk.

Qubik are proud to have supplied and installed the new milking system and water reticulation for Astra Farms.

SPEAKE

Page 36

Coast & Country

Peat soil?

No problem!

MacKenzie Dyer

Cambridge farmer Mark Speake in his 25-bail herringbone shed.

The bladder a year after installation.

When Mark and Fiona Speake purchased their Cambridge farm 12 years ago, they knew exactly what they were in for – they bought the land from Mark’s father, Colin.

“We did a farm swap,” says Mark.

“He wanted the lifestyle, so he bought my 38 hectare Kaipaki farm, and I bought this one. It is where our three daughters have grown up.”

The property sits entirely on peat soil, but Mark and Fiona take their foundations in their stride.

“We are the lowest farm in our area. The next farm is a half a metre higher, and they keep going up from there.

“It’s soft and wet like a sponge, and can be horrible in winter – but it grows great maize.”

A significant challenge of having a peat farm? Choosing an effluent system that won’t sink.

After three years of careful research and consulting, the Speakes settled on the Technipharm Flexitank R – a nutrient capture round bladder system, which they installed at the end of 2019.

“We are always looking to run more efficiently and sustainably, and the Flexitank R bladder allowed us to do that. Our planning paid off, because we wouldn’t swap to anything else.”

Choosing wisely Before getting the Flexitank R, effluent from the Speake’s shed would pump directly into a main holding sump and then to the irrigator.

While this was ideal for nutrient retention, they sought a buffer so they could work more effectively with their effluent and work around the weather.

“We lease the neighbour’s farm that has a sump and a holding pond. It has 3 million litres of rainwater just sitting there, and when we got it tested it contained very little nutrients. In short, we had plenty of reasons not to install the same system on our home farm,” says Mark.

“We didn’t consider getting a bladder until very late in the picture. They were relatively new to the market then, with only two companies selling them.

“Going with Technipharm wasn’t a difficult choice, because they’re a renowned business with a good reputation. We bought a

Dungbuster auto yard-washing system from them more than 15 years ago that has never had any issues, so we were confident we’d get a high quality product.”

Beating peat Mark says it’s common for visitors to the farm to mistake the bladder for an effluent pond with a lid on it. At a second glance however, you can see that the structure sits entirely above the ground, meaning no earthwork is required for installation.

Technipharm NZ CEO Harmen Heesen says this makes the Flexitank R ideal for complicated soil situations.

“Often we place them on farms where there is limited soil material available, the water table is really high, or on unstable ground, like peat, where anything being placed without a foundation would simply sink.”

Page 37

SPEAKE

PH 07 578 0030

Effluent is pumped into the bladder’s centre.

A crane dropping the Flexitank R into position.

Cambridge farmer Mark Speake, left, gets a helping hand to roll out the Flexitank R.

The pipe that empties the bladder back into the sump.

The bladder’s installation on a sand bed.

“In saying that, they can be put on farms with any soil type, it is just a matter of having a surface that is not penetrating to the material.

Therefore, for something like clay, we would put a geo textile layer between the clay and the Flexitank R.” When installed on a peat soil farm, a layer of sand is placed before the Flexitank R is rolled out over it.

The structure The Speake’s bladder holds 1 million litres (1000 cube) of effluent from their 240 cows, calculated in relation to their water usage using the Dairy Pond Effluent Calculator. Harmen says the Technipharm product can come in any size depending on the result of the calculation.

The Flexitank R bladder is essentially a sack, made from nylon fiberglass mesh material fused with a composite liner that is strong, completely waterproof and has internationally

accredited certification.

Effluent is pumped from the existing sump to the centre of the bladder, and when it is dispersed throughout the rest of the structure, the natural movement ensures solids don’t settle.

When required the effluent is syphoned back into the sump, ready for the sump pump to pump it to the irrigator.

Having no solids build-up is easily achieved in the circular system, as there are no corners.

“Corners are a weak point in any system — so the bladder is stronger for having none,” says Harmen.

The centre is equipped with a manhole, allowing a stirrer to be installed if required.

Mark says draining back to the sump is easy. An automatic valve at the sump controls the inflow and shut off, so when the pump is going the inflow to the sump is automatically controlled.

“It saves a lot of labour – you certainly don’t want to be walking back and forth waiting for

1 million litres of effluent to drain,” says Mark.

And having a fully contained system comes with plenty of perks. The room inside is completely utilised, as the bladder doesn’t collect rain water, says Harmen.

“If you have the pond equivalent, you have to allow for rainwater and sludge that can’t be pumped. In some cases, that can take up onethird of your storage facility, which is space you still have to pay for.”

Most importantly for Mark, the bladder retains the effluent’s nitrogen and stops it from evaporating into the atmosphere as greenhouse gas.

“The science behind growing pastures is the thing I love most about farming. Losing nitrogen is such an unnecessary waste when you can use it to grow good grass.”

As a comparison, Harmen says you can lose up to 60 per cent of nitrogen in a couple of

months by using an open system.

Enclosing effluent also means containing the smell that comes with it. Because of this, the Speakes were able to put their Flexitank R right next to the tanker track, and relatively close to the shed.

“There’s no flies buzzing around it or crusting – it’s a very clean and tidy system.”

Into the future The Dutch-made Flexitank R has a 20-year life time expectancy warranty, but Harmen says he’s seen ones in Europe last upwards of 30 years.

The manhole in the centre of the system also allows for it to be cleaned out, rolled up and moved to a different location.

“Having an effluent system we can take with us if we decide to move is the icing on the cake. It has further justified a very worthwhile investment,” says Mark.

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Page 38

CF PARTNERSHIP

Coast & Country

under cover Steve Edwards

Dean and Ang Finnerty with some new additions.

The new dairy goat milking parlour.

Creature comfort is the key at a dairy goat operation in the Waikato.

Dean and Ang Finnerty run a herd of 700 near Morrinsville, which live in luxury under cover all-yearround, with direct access to their new milking parlour.

The couple own a combined 138ha on both sides of Paeroa-Tahuna Rd, with the goats on 38ha. A 285-cow dairy herd is milked in a 32-aside herringbone on the other side of the road.

Dean and Ang purchased the properties seven years ago. They’d been thinking about moving into dairy goats “for years”, with Ang’s brother part-owner of a goat farm.

On December 27, 2018, an option came up for shares – they supply the Dairy Goat Co-operative in Hamilton – and goats from Puketaha.

Shed research Dean and Ang travelled around the country researching shed and equipment options.

Knowing little about the industry, they also spoke to family friends.

They decided on a 50-aside herringbone option, with two rows of cups that means they can milk 100 goats at a time.

Milking is undertaken year-round, with 250 goats in the winter herd. The site was cleared of a former cowshed, making way for a new goat barn and milking parlour built during 14 weeks.

“Only a round barn, now used for kidding,

Proud Service Partner of:

was left when we started,” says Dean.

The goats’ new home is 120m long by 48m wide, with pens and associated feeding units.

Dean says the goat barn, completely covered with a roof supported by treated wooden poles, has skylights in every bay to give the goats well-lit surroundings in natural light.

Goats are also protected from the elements with curtains on the sides and front of the barn. “It’s warm in winter and cool in summer,” says Dean.

The sand base is covered in wood shavings, scraped out and replaced twice-a-year.

Dean and Ang say they were advised that milking goats run outdoors are more subject

The pit area in the 50-aside herringbone. to worms and sore feet than those housed in a barn. Milk production is also reportedly higher from an indoor herd. “Most milking goat herds are now kept housed indoors,” says Dean.

The goats’ diet includes meal, brewers’ grain, grass silage and fresh-cut grass from the farm.

Grain is also fed individually in the bails of the milking shed.

Ang says the herd is predominantly Saanen, a white Swiss breed, with some coloured Alpine cousins with this breed originating in the French Alps. The goats literally walk out of the barn and into the milking shed.

Well fed Dean says no backing gate is required in the holding area, with the goats enticed into the bails by individual feed troughs.

Page 39

CF PARTNERSHIP

Wade Contractors’ director Klinton Wade.

Don Chapman Waikato director Shanan White with Chapman Dairy director Don Chapman.

Ang and Dean Finnerty in their new dairy goat milking parlour.

Goats are kept warm in winter and cool in summer in their new barn.

Adapted for goats The operation also includes a new tanker loop and driveway from the road, plus an implement shed.

Shed design was undertaken by Chapman Dairy and construction by fellow Morrinsvillebased business Don Chapman Waikato. This was the biggest goat milking parlour both companies had been involved in.

Chapman Dairy director Don Chapman and Shanan White, director at Don Chapman Waikato, say features of the project included

The pit was then dug, with Wade Contractors BCL Feed Systems also involved in forming the new tanker loop

the depth and width of the pit, and rapid exit from the bails.

Overall, they say the parlour chiefly involved adapting a traditional dairy cow herringbone to suit milking goats. “The details were pretty standard,” says Don. This included the rooms housing the milk SILO’S 2T-45T plant and washdown systems, which Don and Shanan say were in line with a dairy cow operation, while vats holding the goats’ milk for collection are indoors.

A site meeting was held in January, with two-three of Shanan’s staff on-site for 14-weeks.

Earthworks were completed by Wade Contractors from nearby Te Aroha.

Director Klinton Wade says four staff were on-site for two weeks. Initial work involved stripping the site for construction of the goat barn and milking shed. “The existing cowshed was demolished and the site then filled with sand and laser levelled,” says Klinton.

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and driveway from the road. The milking plant was provided by GEA Farm Technologies.

GEA Farm Technologies sales manager Grant Coburn says a number of factors were considered going intoIN-SHED the project including HERRINGBONE FEEDING herd size, milking time and automation. “We were looking at a maximum of 1000 goats and spending no more than two hours in the shed for each milking.

“They wanted a nice open, clean and tidy system.” Grant says the plant also needed to be “low-line”, with no pipes or equipment above the heads of the milking staff.

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Ang’s property goes into infant formula produced by the Dairy Goat Co-operative. Dean also enjoys a drop in his tea in the morning.

The goats are fed 400g of meal each in-shed per milking. Washdown of the bails and yard is undertaken by the good old-fashioned highpressure hose. Effluent goes into a tank and is ultimately spread on pasture.

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The goats face out from the bails during milking and have a ‘quick exit’ back to their barn, not travelling in a row as in a traditional herringbone cowshed.

Dean says they took only a week’s training, having had previous experience in other milking sheds.

“A wide pit – more than 2m – accommodates cups on either side instead of the traditional central, single row.”

Dean says the 700 goats can be milked in just 90 minutes, each producing about 4.6 litres-aday in two milkings.

Two staff are in the milking shed, with six employed during kidding. Manual cup removers and teat-spray have been installed initially, but Dean says the systems will both eventually become automated.

The milk plant, refrigeration and washdown systems are similar to a cow milking operation, says Dean. The end product from Dean and

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Page 40

Coast & Country The in-bail feeding system.

The milking parlour features a ‘quick exit’ for the dairy goats.

The walkway into the milking parlour.

And milking is “simple but effective”. “The size of the clusters is obviously different for goats compared to cows and similarly, speeds are different for the pulsators.” But much the same equipment is used for the milk plant and washdown.

Grant says automatic cup removers are planned for next season – with 750 to 800 goats likely to be going through the shed – while there is also scope to replace the manual cup-wash system.

Morrinsville-based McLarens Rural Services installed all the milking plant “from goat to vat,” says director Tony McLaren. “It is similar to a dairy cow operation, except for the speed of the pulsators and smaller/lighter claws,” says Tony.

In the plant room, McLarens installed the plate cooler and vacuum system. Tony says his company also handled all water works including

the washdown, cooler and chilled water pumps.

A pressure pump was installed for the shed toilet and handbasin, while McLarens connected the milk line and wash system for the vats.

Two-stage barn The goat barn was designed and completed by Aztech Buildings.

Project consultant Daniel Prestidge says the project was undertaken in two stages, one year apart. “This phased-in approach was to allow for better budgeting and quicker construction of the first stage.”

A 78m by 42m barn was enlarged to 120m by 42m to cater for greater goat numbers over time. Working on a green-field site, Daniel says a bedding area was created using wood shavings, with two concrete feed lanes added for a tractor and feed wagon to drive on. “Treated timber poles set in concrete support the roof, which features steel framing

Two 16-tonne silos, installed by Buster Cover, supply feed to both the milking parlour and goat barn. and ribbed profile iron.”

Daniel says the design also uses skylights in the roof to make the most of natural UV light.

“Animal welfare is key,” says Daniel. “You want to create an environment which is best practice for goats.

“If they are comfortable and well fed, they will produce more milk.”

Daniel says research shows dairy goats properly housed in an Aztech barn can produce twice as much milk as those living outside.

“The barn is warmer in winter and cooler in summer, but minimising vast temperature fluctuations is actually critical too for good animal health.”

Extra features Bedding area space for each goat is also critically important, says Daniel. “Similarly, the goats need to have an adequate feed space so they get their fair share.”

Other key factors in the barn design is its ‘perch-proof’ rafters to keep bird diseases away,

The nerve centre of the milking area, installed by GEA Farm Technologies.

and excellent ventilation to control ammonia levels and maintain a dry barn.

The barn links directly to the milking parlour, meaning just a short walk for the herd. “Flow is important,” says Daniel. “It needs to be streamlined and efficient. Aztech barns are not only great for dairy goats but also for the farm worker.”

Feeding systems in both the milking shed and goat barn were installed by Matamata-based Buster Cover.

Foreman Bill King says a 16-tonne silo feeds individual bins in the bails, via a PVC pipe using a spring-loaded auger powered by a 1.1kW motor. “A sensor detects when the bins are empty and activates the delivery system,” says Bill. Another 16-tonne silo is used to fill a feed-out wagon, using a six-inch solid auger.

Powered by a 2.2kW motor, Bill says this can load a tonne of feed every three minutes.

“And the systems can handle all types of feed.” Two staff were on-site for a week to set up the feed system.

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Centralised

MOORBY

Coast & Country

Steve Edwards

John and Debbie Moorby.

Super staff: Left (front to back): Debbie Moorby, Marino Rimene and John Moorby. Right (front to back): Monica Knight, Matthew Hina-Ferris and Ronnie Bird.

Considering their dairy farming journey, it is rather fitting that John and Debbie Moorby live on Long Rd. Based near Te Awamutu in the Waikato, the couple have graduated through the dairying ranks over the last 35 years, now milking 1140 cows in a spectacular new shed.

John and Debbie say the centralised operation, built by long-time business associates Gibson Construction, was in the pipeline for a decade.

The 80-bail Centrus Composite rotary shed, fitted out by Qubik TMC, also includes a large feedpad and associated effluent disposal system.

Local links Four years ago the rotary shed came to the front of John’s mind and he started chatting about the project with Ken Osborne, who is

CEO of Qubik, visiting some similar-type sheds in the South Island to glean ideas.

The 80-bail rotary quickly became the preferred option for the expanded operation, with Ken his “sounding board”.

In recent years John and Debbie have expanded their operation to both sides of the road, now running 355ha in total. They’d previously milked 640 cows in a 44-aside herringbone.

John says several on-site meetings for the new shed were held with the contractors before physical work began late-2018, with the first milking completed in July 2019.

Central site The site’s central location was chosen so cows would have to walk no more than 2km to the shed, including those on the other side of the road via an underpass.

John says the relatively flat green-field site meant earthworks were “not a major”, with topsoil sourced from the home farm. He and a staff member pitched in with tractors and trailers.

Gibson Construction used a different process for the Moorby shed compared to traditional methods, says project foreman supervisor Mikey Broadley.

After a sand-pad was created, the roof was put on first rather than being the last step.

Mikey says this meant contractors could work in all weather.

“This was a massive saving,” says Mikey. It also ticked off a “big box” for worker safety, particularly electricians fitting lights to the building.

Another feature, which Mikey says helped contractors immensely, was an underpass from the shed into the pit area.

Qubik are proud to have supplied and installed the new milking system, water reticulation, effluent system, refrigeration and pre-cooling system for John and Debbie Moorby.

An aerial view of the Moorby farm dairy.

Photo: Gibson Construction.

The milking platform has an 11m radius, while the yard is 18m in radius, with a 100m by 30m feed-pad. The entire footprint covers about 270m in length.

The herd is split into three for milking purposes, with technology including automatic cup removers and washdown “freeing up” staff time. Two people can now handle milking duties instead of five with the previous twoshed operation on both sides of the road.

Dynamic drafting The shed also features a Protrack drafting system, provided by LIC Automation. National sales and product manager Jason Quartier says the Protrack Rotary ID system has a three-way drafting gate which uses an electronic reader and antenna to identify an animal by eartag number as it enters the bail.

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MOORBY

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Qubik CEO Ken with Debbie and John Moorby, Qubik refrigeration sales manager Nick Heffer and milking machine sales/effluent design consultant Kyle Osborne.

John Moorby with LIC Automation’s Jason Quartier in front of the Protrack drafting gate.

The 100m by 30m effluent pad is the largest ever tackled by Gibson Construction.

Linked into a computer system in the shed office, this allows milkers to easily update and record animal events such as mating, health treatment, calving, pregnancy diagnosis and herd testing.

Jason says LIC kept in close contact with Gibson Construction on positioning of the gate in the shed complex – animal entry and exit from the milking platform – with two holding pens also created.

The milking area features a separate foldout platform, for AB and vet use, created by Gibson Construction.

Qubik installed the Waikato Milking Systems electronic bail gates, milking plant, chillers for milk and water, vacuum and washdown systems. The milking platform rotates on a multi-roller system designed by Waikato Milking Systems.

Milking made easy Qubik operations manager for milking machines Jeremy Collett says the Centrus rotary platform is made from composite mate-

rials “making it lighter but stronger than others on the market”.

A floodwash system was installed on the feedpad, using green water from the shed during milkings, stored in two concrete tanks.

An 18.5kw Lowara variable speed pump runs effluent through to a Cobra travelling irrigator, to be spread on the farm.

Three 800L water cylinders were installed by Qubik. Jeremy says visible pipework is noticeably absent, with hot water inlets and outlets incorporated in the stainless steel cylinder frame.

The shed also has Waikato Milking System’s new ECR PLUS cup removers. Waikato Milking System sales manager Paul McGill says this new product lends itself to future automation in other areas of the plant, which can futher reduce labour.

“ECR PLUS is fully integrated with SmartSPRAY, an automatic teat-spray system, supplied

by Waikato Milking Systems and installed by Qubik, fitted to every bail.” And Paul says a variable speed vacuum system “reacts” according to the number of cups in use.

Moa Rotary Platforms installed the 80-bail Centrus composite platform for the Moorby shed at Te Awamutu. Moa’s Nicky Smith says the customer went for Waikato Milking Systems new multi-roller system with nylon rollers instead of steel as it has less wearing parts. “This means there will be less maintenance required in the future.” The team at Moa also installed stainless steel feed bins.

Cows receive up to 1kg of meal each while being milked, via a system installed by PPP Industries.

PPP Industries installed a model 350 auger line with a platform feed dispenser controlled by the Protrack system.

General manager Nick Morison says fitted outside the shed are two 16-tonne silos to house the meal, with ladders and safety guards.

“PPP also installed a molasses injection system, including a 30-tonne molasses tank.”

John and Debbie opted for a Dungbuster automatic yard washing system, suspended under the backing gate and supplied by Technipharm International.

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Qubik operations manager milking machines Jeremy Collett, with Waikato Milking Systems’ regional sales manager Waikato/ Northland Gary Feeney and Qubik CEO Ken Osborne.

Fully Fenced, from nearby Ohaupo, undertook fencing work, including posts and rails on the roadside and tanker track, and regular batten and wire for the lead-in races and around the shed. The work also took in fencing associated with an underpass linking the two properties. Managing director Sean O’Halloran says four staff worked on the project for about a fortnight.

Lining it Hamilton-based Enviroline NZ installed the effluent pond liner, with four staff on the job for three days.

Owner-operator Andrew Forbes says the 50m by 60m by 4m high density polyethylene liner was made on-site, with 7.5m wide sheets “welded” together. “The finished pond is capable of holding nearly 9000m3 of effluent,” says Andrew.

John and Debbie opted for the Race Works Wrangler for hassle-free hoof care of their herd. The galvanised iron unit supplied by Whakatane-based The Wrangler, provides “total safety” for the cow and the farmer, says founders Wilco and Waverley Klein Ovink.

Waverley says The Works unit features winches for the animal’s front and back legs, fitting all sizes of cow.

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NEW FARM DAIRIES

Coast & Country

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60 FARMS

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Total

Coast & Country

Steve Edwards

The nerve centre of the pit operation.

‘Keep it simple’ was the philosophy used in a new farm dairy project in Northland.

“The less complicated it is, the less can go wrong,” says Dan Knibbs, who is overseer/ manager of the 113ha property at Ruawai near Dargaville.

A cup cleaning system is the only mod-con in the 40-aside herringbone shed, which has stuck with manual cup removal and teat-spray systems.

The big difference is a jump in bail size, from 14-aside to 40-aside, which Dan says provides a huge saving in milking time. “This accommodates 360 cows, all pure Jersey, up from 180 three years ago.”

Looking to milk 400 cows next year, Dan says a 40-aside herringbone was the most efficient option.

Time-saver The herd can now be milked in nine rows, and well under two hours. Dan and his wife Leisha manage four properties in the area, co-owned with her parents Greg Gent and Ann Flood.

A former Kaipara Mayor, Greg is well-known in dairying circles as a Fonterra director from the formation of the co-operative after previously leading Northland Dairy and Kiwi Co-operative Dairies.

In 2012 he was made an Officer of the New Zealand Order of Merit in the Queen’s Birthday Honours list for services to the dairy

Dan Knibbs is enjoying the change from corporate life.

The Ruawai dairy shed is a blend of new and existing facilities. industry and corporate governance.

Greg started out in dairying at Ruawai on his parents’ property, milking 70 cows. Originally from England, Dan Knibbs decided to leave the corporate world in Wellington and go back to the farm Leisha grew up on. “We wanted to work for ourselves.”

Dan says the operation has really come full circle with Leisha back on the farm the family has occupied for more than a century.

Dan and Leisha bought 9ha off a neighbour in their first season and the following year leased a further 15ha and bought a herd.

Another 26ha block owned by Greg and Ann was incorporated into the milking platform for the current season.

However, milking 18 rows in the small herringbone on Mitchell Rd became too much

and in early-2019 they opted for a bigger shed to handle the bigger herd.

The revamped shed has almost tripled the size of the footprint of the facility at Ruawai, says Dan. They were able to use the existing plant room, milking area and part of the yard in the development project.

Some earthworks were required to accommodate the new layout, which was undertaken by farm staff. Building began in April 2019, led by Barfoote Construction from Whangarei.

Plan change Barfoote Construction director Trevor Barfoote says a meeting with Dan saw the original plan for the complex changed somewhat.

“They were looking to tack on a new piece to the old one.”

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60 FARMS

FIL Northland area manager Brian Salvigny.

‘Keep it simple’ was the philosophy used in the Ruawai project.

Looking out from the expanded farm dairy at Ruawai.

Dan says they had an idea at the beginning that “we thought would work” involving adding on to the existing yard. However, Trevor suggested the old yard could be used as an exit race and a new yard developed. “For practical reasons we flipped it around,” says Dan. The old shed dated back more than 30 years. “Really just the main wall and the milk room were left,” says Trevor. “We came up with something almost new.”

Trevor says it would also have been difficult to integrate roof styles, going from 14 to 40 bails. This saw his company build a full, round yard, including an entranceway from the farm race and the entrance area to the bails.

Barfoote Construction, which recently marked 30 years in business, also developed a new pit and bails to accommodate the greater cow capacity. Three staff from the company were on-site for about eight weeks. Dan says the yard can accommodate up to 800 cows, future-proofing the operation.

DeLaval, which provided the milking plant in the original shed, again came on board for the new facility.

FIL Northland area manager Brian Salvigny provides the Quantum Red dairy detergent used in the plant washdown.

DeLaval, which provided the milking plant in the original shed, again came on board for the new facility at Ruawai.

The company supplied a variety of equipment including a LVP 3000 vacuum pump, two auto-fill hot water cylinders, a 250 litre and 350 litre, with associated tub, filter housing and plate cooler.

The DeLaval herringbone milking plant includes a variable speed milk pump, driven by a 2.2kW motor, plus the clusters and associated washing system.

from Ruawai. In preparation for the building and concrete-laying, Glen says a fair bit of material was required to build up the area around the old cowshed site – 1.5m – to accommodate the new facility. “There was a steep drop-off, and we started from scratch.”

Using a 12-tonne roller, Glen built up the area using quarry slippings from Ruawai.

Tried and true

New races

Dairy detergents for the new shed were provided by FIL from Mount Maunganui. FIL’s Northland area manager Brian Salvigny says higher spec products are used because of the hard water – with high iron and manganese components – in Ruawai water.

“So 500ml of detergent – Quantum Red – is used for each wash, which is standard for the size of the operation. This is mixed, via a detergent dispenser, with hot water in a tub and sucked through the milking plant by a purge cleaning system.” FIL also supply the iodine-based teat-spray, applied by farm staff using hand-held sprayers after each cow is milked.

Earthworks on-site were completed by Glen Jenyns’ Excavators

Glen also developed new races, stripping off topsoil and replacing it with metal. “The property, on a former swamp, has a sandy base.

It’s quite sticky. Typical of Ruawai land, it can become very wet in winter and dry in summer.”

Glen also previously dug a new effluent pond on the property.

The Ruawai shed was commissioned on July 20, 2019.

Dan has two staff working on the block. “Our ethos is to bring young people into the industry.” Calves off the four dairy farms owned by Greg and Ann are all used for beef. Dan also manages the fifth farm in the family portfolio, a former forestry block converted for cattle. This 600ha block runs more than 2000 beef cattle.

CRAWFORD

Page 48

Coast & Country

Feed pad Steve Edwards

An Ag ITO project by Brenda Crawford, pictured with husband David, was the catalyst for the standing area.

A covered feed pad/standing area saves a marathon trek for cows on a Northland dairy farm.

Instead of hiking up to three hours-a-day from the most distant paddocks, to and from the milking shed, the Crawford farm herd at Tangowahine near Dargaville can shelter from the elements while being fed and watered in a ‘Smart Shelter’.

David and Brenda Crawford converted to dairy in 2009, running a 400ha ‘home farm’ and a 100ha run-off – over three blocks – with the herd size jumping from 280 in the first season to 560 this year through the addition of two neighbouring farms.

Milking year-round, they have separate autumn and spring herds – mostly Friesian, with some cross-bred and Ayrshires adding to the mix.

The catalyst for the feed pad was a project

Brenda undertook for her agribusiness ITO diploma.

In her report, Brenda says winters in the area can be extremely wet “which can result in sore feet for the cows from having to walk off the hills to and from the cowshed”.

The farm has also experienced “extremely dry” summers in recent years and is subject to south westerly winds.

Dry spell “During the summer months this area can be particularly dry – the flats and the hills – making pasture growth difficult to nonexistent,” says Brenda.

David says they talked about making the feed pad become a reality, with construction undertaken towards the end of last year.

The farm had an existing 16m by 70m concrete pad, but he says this was uncovered, with

David Crawford outside the new feed-pad. no surface matting, and wasn’t being utilised to the maximum without cover.

The pad has been extended to 25m by 70m, capable of holding 280 cows.

Water and feed troughs are incorporated in the design, with the cows’ diet including grass silage, maize, kumara and PKE. “Putting in the feed pad enabled us to feed the cows extra feed without damaging the pasture and soil, and it gives us flexibility,” says Brenda.

It has also been estimated that cows using the feed pad during summer produce an extra four litres of milk per day each when not facing a marathon walk to the milking shed. “It pays for itself,” says David.

He recommends the feed pad “one hundred per cent”. “It’s cheaper than having a run-off, there’s no waste of feed and everything is central.”

Cows remain on the feed pad after morning milking, heading out to pasture in the evening.

David says keeping cows on feed pads for longer is becoming more common in dairying.

“You protect pasture, and production is already increasing.”

An added bonus is rainwater from the roof of the feed pad goes back into the farm system.

“We get about 1.4 million litres a year of good water,” says David.

The pad was built by Dargaville-based Vuletich Construction. Director John Vuletich says the work was undertaken just before Christmas in 2019.

Around 550 square metres of concrete was used in the project, taking advantage of the existing smaller pad, and included 80 cubic metres of concrete in the floor.

Fibre reinforcing John says plastic fibre was used instead of the traditional steel for reinforcing in the concrete.

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CRAWFORD

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Cows are protected from the elements year-round on the Crawford farm.

John Vuletich, director of Dargaville-based Vuletich Construction, which laid the concrete base for the pad.

“This provides some ‘give’ in the surface and is a cheaper option – through time and labour – than steel.”

Five staff worked for three days on the site.

Vuletich Construction also built the cowshed for the previous owners in 2001.

The 28-aside herringbone is on the site of a former wintering barn, with a yard capable of holding 300 cows.

Auckland-based SmartShelters provided the roof for the new feed pad. Sales consultant Brett Cottle had discussions with the Crawfords about the project in May 2019, with a variety of sizes and layouts considered.

“Brenda’s ag ITO report played a key role in this preliminary work,” says Brett.

Brett says a big part of a project of this nature is compliance – industry and local authority – “and about getting ahead of compliance”.

“The key to the Crawford structure is its big,

Cows are well fed and watered in the new structure.

clear span,” says Brett. “There are no supporting poles inside, making it clear for the associated flood-wash system.

“The roof is polyethylene fabric, with a mesh interior, made in Canada.”

Brett says material required to cover the Crawford feed pad has a 22m span and is 50m in length.

“Letting in natural light, cows are kept cooler in summer and warmer in winter.

“SmartShelters are up to 12 degrees cooler in summer, giving cows heat-stress relief and up to 0.4kgms-a-day production increase.”

The roofing material goes over galvanised steel framing, attached to large treated timber poles which are cemented almost three metres into the ground.

Matting for the standing area was provided

by Numat Industries from Oamaru. Agri sales consultant Anthony Garton says a Kura

Numat matting helps prevent lameness in cows and is easy to clean.

product was used, providing cow comfort and an easy-clean surface. “It’s good quality, hardwearing and good for cows to stand on.”

Anthony says the matting is made in Germany where cows are housed all-year-round.

Cushioning Rubber studs underneath the material provide a cushioning effect. It is laid in interlocking squares – “like a big jigsaw puzzle” – which Anthony says allows the material to expand and contract during changes in outside temperature.

He says the matting is secured to the concrete base by a stainless steel anchoring system.

Numat also previously supplied and laid matting in the Crawford dairy shed.

Anthony says the Legend product that was used, was made in Canada. “It was laid in the

yard and bails, once again aimed at cow comfort and preventing slipping on the concrete surface.

“It’s also about cow flow,” says Anthony.

“Cows move better on rubber.”

He says the Legend material has more grip than that used on the feed pad.

Similarly, it is laid in interlocking squares in the dairy shed using the same fastening system as that used in the standing area. David says matting, already used in the cowshed, was always “part of the plan” for the feed pad.

“Walking or standing on concrete can be brutal on cows.”

Brenda says the matting is also easy to keep clean. The pad is washed down using recycled green water from the cowshed, housed in three 25,000 litre floodwash tanks.

“The gravity-fed system operates for two minutes per wash on a timer, with material going into the farm effluent pond.”

DUNROAMIN LTD

Page 50

Coast & Country

Lois Natta

Partnership by choice.

Looking up the road towards the McLaren’s immaculate new shed at Tirohanga.

Bruce McLaren’s father, Jim, being a returned serviceman was allocated a Tirohanga farm back in 1958.

All war veterans were able to put their name down for a ballot farm from the Crown allotment. There were conditions for eligibility for farms, including previous farming experience and how much personal money the applicant had available to put into the farm.

On qualifying to apply for a farm, the applicant could choose which farm settlements they would prefer and, if there were more than the required number of applicants, which was usual, for that settlement, a ballot was held that participants could attend and know the results immediately.

Bruce’s parents Jim and Avice won the ballot for the Tirohanga farm, which meant a shift from Pukehina in the Bay of Plenty to

Tirohanga in Taupo with three school-aged children. Bruce remembers the shift well, and says they used a truck to move their belongings, and not the horse and cart I assumed it may have been – oops!

The ballot farm originally had a four-bail walk-through shed milking 90 cows, plus a house.

Expanding The 56 hectare farm was made up of eight paddocks, which meant Jim did a lot of pasture renovation work and fencing to make the farm more manageable. Over the ensuing years after taking the farm over, Bruce and wife Bev purchased three neighbouring properties

and they now have a 210ha farm.

An upgrade in 1993 meant the farm, owned by the couple, was equipped with a flash new 30-aside herringbone shed.

This was utilised very successfully until a decision was made to either spend a lot of money upgrading the herringbone, or build an entirely new shed. The new shed was the preferred option, which has been sited not too far from the old herringbone.

Son Scott McLaren and his wife Paula now contract milk the farm, while the couple’s other son Tony McLaren, who runs a successful contracting business, does all his pasture renovation and earthworks. Bruce is really proud of the whole set-up. “I can’t

pinpoint one single thing, I’m just really proud of the whole thing,” says Bruce.

Replica Bruce’s son Tony who, with wife Kim own McLaren Contracting, upgraded the races, did the site prep for the new shed, dug out the effluent pond and ensured the tanker track was up to regulation. He also contoured and re-pastured many paddocks for Bruce. The farm genuinely does look amazing and it is easy to see the specialised job that’s been done by Tony, has indeed been done to a very high standard.

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Page 51

DUNROAMIN LTD

PH 07 578 0030

Broomfield Construction’s Rob Broomfield at the underpass entry.

Laser Electrical Putaruru’s Chris McKillop demonstrating the fuse boxes.

Mainland Engineering’s Daniel Gorton is particularly proud of their hand washing facility.

GEA New Zealand’s Grant Coburn showing off the CowScout Neck band.

The new shed was built by Broomfield Construction from Morrinsville. Bruce had viewed a shed previously showcased in New Farm Dairies that he wanted a replica of, which so happened to have been built by Rob Broomfield and his team.

The new 54-bail rotary has plenty of space, and consists of the usual array of rooms such as kitchen and office space, toilet, storage room, pump room, and a vet area is housed to one corner at cups-off with a drop-down vet platform. There is an animal-handling area to one side of the shed with plenty of

roof overhang to keep people dry during bad weather. An underpass, from cups-on to cups-off area, as well as entry into the centre of the platform has been well constructed.

Safety firs The entry to the platform centre is equipped with a pool gate-type system that has a key that will switch the platform off so someone can enter the platform centre safely. The walls are constructed of concrete block, and insulated poly panel for ease of cleaning. The centre

Farmer Bruce McLaren opening up the feed bunker. of the roof has clearlite to allow plenty of light into the shed, and is fully bird-proofed. The milk silos are sited undercover to the side of the shed, with entry to the shed from various locations. Broomfield Construction also constructed the covered chemical bins to the side of the shed, the generator shed, and effluent bunkers.

Due to health and safety regulations, new dairy shed builds now must house certain chemicals in bunkers to prevent them from coming in contact with each other and forming

noxious gas. Rob constructed the bunkers with a decent-sized drain to contain spillages if they happen. The chemicals will remain in the drain until pumped out and back into their container.

Minimal maintenance Bruce chose the GEA milking system solely on the base of the platform. “The reason being,” says Bruce, “is that the platform is on nylon rollers with double I beam making for minimal maintenance”.

Office / After hours 07 377 2941 E office@mainlandeng.co.nz A 16 Miro Street Taupo Office Office//After Afterhours hours07 07377 3772941 2941 EEoffice@mainlandeng.co.nz office@mainlandeng.co.nz AA1616Miro MiroStr St

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Page 52

The chemical bins in the process of having a roof put over them.

Looking into the McLaren’s new shed at Tirohanga.

The block work has been coated in Acraflex paint

by Modern Coatings from Waiuku and stands the test of time.

Installed by Mainland Engineering, the 54-bail iFLOW rotary GEA milking system comes equipped with automatic cup removers, cow restraints and an automated wash system.

All the machinery is located in the centre of the platform, which is accessed via the underpass.

“Bruce started milking in the shed in May of 2019, as he wanted to get his cows in and used to the new shed before calving,” says GEA New Zealand senior account manager Grant Coburn.

A breeze In the yard a Technipharm Dungbuster effectively removes the bulk of the poo so that end-of-milking washdown is a breeze.

Coast & Country

Inside the shed Mainland Engineering installed the feed bins and model 350 auger lines, which are controlled via a PPP control system that recognises and does not supply empty stalls if an individual animal is going around for a double lap. Stainless steel trays come with two drains plugs, complete with bolt-on hot-dipped antirobbing bale dividers and underneath tray supports.

PPP supplied to Mainland Engineering a 20 tonne silo and a 30 tonne silo. The two silos are located outside of the shed, and are fed from a feed bunker that I’ve never seen at any other shed. The feed bunker, which is constructed of concrete blocks, has enough

The shed is fitted out with these impressive LED lights.

The clearlite centre roofing allows plenty of light into the shed. space for the feed truck to back into and when lined up correctly deposits all the feed from the truck into the auger at the end on the concrete feed bunker. Both silos are filled directly via a 200mm auger from a bunker that is filled directly from the truck.

We made it happen As well as installing the milking plant and feed system, Mainland Engineering from Taupo also installed the water system.

Mainland Engineering owner Daniel Gorton says he’s particularly proud of the handwashing system they installed, which turns off automatically.

“It was Bruce’s idea, but we made it happen.”

The entire herd has been fitted with GEA CowScout collars, which monitor the cow’s activity and eating times. The alert function quickly advises if the cow is exhibiting feeding or health problems so that the farmer can react quickly and appropriately. CowScout measures the amount of time the animals spend eating and will produce an alert if this differs from the previous ten days eating habits.

CowScout also gives a constant heat monitoring and display of optimal insemination time, which means they do not need to spend time watching for heats. The CowScout system controls a drafting gate which automatically drafts out the cows when they are ready for mating.

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Page 53

DUNROAMIN LTD

PH 07 578 0030

Bruce McLaren’s son Tony McLaren, who with wife Kim own McLaren Contracting, did all the pasture renovation, site prep and raceways.

The feed bunker is set up to fill the PPP feed silos.

Internet connection means that data can be accessed anytime and anywhere on a mobile phone or any other PC or tablet with internet access.

Wide electrical scope Laser Electrical Putaruru was commissioned to undertake the full electrical installation and given a wide electrical scope, which included full automation for the cowshed, wash, effluent, water and feed system.

Laser Electrical Putaruru owner Chris McKillop says the McLarens were a pleasure to deal with “and were open to suggestions put forward by Laser Electrical”.

Automation was achieved using a

Programmable Logic Controller and HMI Screen for the general running and control of the cowshed equipment, with wireless control and monitoring of the effluent and water system.

“This was an important aspect as the McLarens had three forms of water supply for the farm pressure pump, which was at the new shed so controlling and prioritising each bore pump was achieved using PLC automation and wireless technology.”

“With automation comes the ability to remote access to the farmer’s PLC if internet WiFi is available, so if any technical issues arise they can be diagnosed online and assist farmers remotely if required.”

In addition to the project a generator was

Looking back towards the old herringbone cow shed. centrally located and installed to supply the new cowshed, existing cowshed, houses and pump shed. The generator is manually started, this gives the McLarens surety of power so the everyday operation is not affected, particularly with water supply and milk refrigeration.

Spotted throughout the shed are LED Hi-Bay lights used for commercial jobs.

They have a very high light output, energy efficient and 50,000 plus life so are very low maintenance compared to conventional lighting.

Easy to keep clean All the block work was covered in an Acraflex coating. Applied by Modern Coatings from Waiuku, owner Roger Farley applies multi

layers of various coatings to get the finished look. “The end result looks amazing, is easy to keep clean and makes the new shed sparkle.”

Craig Stevens Motorcycles from Tokoroa does regular services on the farm bikes to make sure they are in good working order. It is vital that the farm bikes are in good working condition, and always safe to ride, says Bruce.

With the shed build complete, Bruce’s phone calls and visits are now directed to Farmlands Taupo and Tokoroa, where he goes for most of his shed and farm supplies.

This is a shed that stands proud on the horizon. It’s one of those sheds that just looks really good when driving by. The farm is neat and tidy and it is all pleasing to the eye.

LAW

Page 54

Coast & Country

Biological farming

Anne Boswell

A refractometer is used to measure pasture quality as part of monitoring procedures.

Alan Law’s neighbour has been observing over his fence for a few months now. He was curious as to what the Laws were doing differently for their Whakatane dairy farm to have withstood last season’s drought with lush, green pasture cover, productive cows, and very little stress.

Last season, it was a different story for Alan and wife Wendy.

Conscientious and proactive farmers, the news that the Government planned to tighten environmental regulations yet again with the National Environment Standard on Freshwater Management was the final straw.

“At 62, I thought: ‘Was dairy farming even worth the effort and the stress any more?’” says Alan.

“It made us realise that our whole business was at risk from government intervention and restrictions, with no recognition of good stewardship whatsoever.

“As we’ve grown our business and increased our mortgage, we

From left: Ron McLean, Alan Law, Karl Stokes, Cameron Law and David Law.

Lush pasture hides a standard pen in April 2020, during regional drought conditions. found ourselves putting on more and more nitrogen but we’ve always known it wasn’t sustainable.”

Alan’s dairy farming career had humble beginnings but his innovative approach and desire to excel saw it grow into something bigger.

“I first purchased 60ha in 1981 and milked 200 cows, and I thought that was me; that would be my career,” he laughs.

“In the 1980s we really struggled through Rogernomics with high debt, but we reared a lot of beef calves and got through that period reasonably well.”

They have slowly grown their family business and today, the family milks 850 cows on 260ha split into three properties, averaging 500kgMS/cow or 1600kgMS/ha.

The couple’s eldest son Brandon contract milks on the Oriini farm, run independently to the other farms, and he also leases a farm next to the home farm on which he milks 164 cows independently.

Youngest son Cameron contract milks 290 cows on the home farm.

“The boys have always been involved in the farm right from the get-go,” says Alan. “They are both very capable young men.”

Historically, Alan has applied urea twice annually: once in spring and once in autumn. However, in recent years nitrogen products were being applied every six weeks, peaking at 180 units/ha of N. After the freshwater management announcement, Alan knew that a more sustainable system was the only way to keep ahead of public and government pressure.

He called in the big guns: his younger brother.

Family ties Most siblings experience a difference of opinion in their lives, and it was no different for Alan and David Law. David farmed across the river from Alan at Thornton and in 2002, he started a transition from a chemical to a biological farming system. David achieved his goal of growing 19 tonnes DM/ha using only 30 units of nitrogen for the season.

LAW

PH 07 578 0030

Kiwi Fertiliser director Brett Petersen holds up a handful of healthy, fragrant soil on Alan Law’s farm.

Page 55

Cameron Law moves a pasture cage back into place after taking a sample for monitoring purposes.

At the time, Alan and David had opposing philosophies with the way the other was farming. David left the farm in 2012 to start his own farm consultancy business, Forward Farming Biological Consultancy, training extensively in soils, fertility and biological effluent management.

Over time, Alan started to see merit in biological farming, and, last season, David presented Alan with a concept he had been working on called Total Replacement Therapy.

The method aimed to improve soil health, establish a strong clover presence and get clover fixing nitrogen naturally – the way it used to happen – so synthetic nitrogen could be reduced dramatically without sacrificing pasture production.

“Total Replacement Therapy is a unique, ground-breaking process that is the result of a team of international specialists combining their expertise in soil biology, chemistry, agronomy and nutrition,” says David.

“The result is growing great pasture with less

Regular soil digs are crucial for the The Total Replacement Therapy team have documented the Law family’s team to visually assess soil structure transition from chemical farmers to biological farmers. and health. synthetic nitrogen, as well as reducing methane Dr William Albrecht, who is considered the The soil sample was sent to Perry and leaching, and increasing soil water holding foremost authority on the relation of soil Agricultural Laboratory (PAL) in Missouri, capacity.” fertility to human health.

US, the exclusive auditor of soil samples Alan says they calculated his average fertiliser His method is based on a system of nutrient taken by those who practice the Albrecht/ spend for the last four years, which was the and mineral supplementation whereby the Kinsey principles of soil fertility. set farm budget. David’s Total Replacement balance between the different minerals is as The results of the soil audit determine Therapy programme recommendation, which important as their quantity. which custom-blended nutrients and trace included both solid fertiliser and biological By using the principles of soil chemistry, the elements are added to the farm’s soil. liquid enhancement, came back at $18,000 correct soil structure can be developed, and The Law farm’s soil composition was under that budget. this provides the basis in which soil biology already reasonably good, thanks to many Alan stipulated the programme could not have can flourish. years of using Sechura Reactive Phosphate a negative impact on the business’ cash flow, Dr Albrecht’s system was further refined by Rock (RPR). profitability or pasture production. one of his last students, Neal Kinsey, who has Once the soil was balanced and conditions “We also insisted everything on the trained and mentored members of the Total were right for good biology to thrive, it was Government’s ‘hit list’ was measured and Replacement Therapy team. time to add the biology to its new home. managed: carbon footprint, soil carbon, status Alan had attended two Neil Kinsey of methane and other emissions, and water seminars in recent years and although Send in the bugs quality,” says Alan. intrigued, had not been confident enough to In October 2019, Wyndlea, the 89ha home change his farming system.

Feed the soil farm, was given its first whole-farm round of The first step of Total Replacement Total Replacement Therapy. An additional Therapy was to take a comprehensive soil The cornerstone of Total Replacement audit on Alan’s farm, carried out by Kiwi 10ha of the 120ha Oriini farm was also Therapy is the Albrecht/Kinsey Soils Fertiliser Ltd. added to the trial area.

Programme: a method pioneered by the late

LAW

Page 56

Cameron Law feeds out on the Whakatane dairy farm.

The pasture cover on Alan Law’s dairy farm defied regional drought conditions and continued to grow strongly

as part of the budgeted plan, and the Laws are planning to use Mylo on the calves they are rearing this spring.

Clover takes over Kiwi Fertiliser’s Gerry Strange applied Terragen Great Land, a liquid biological conditioner, along with Biomarinus fish fertiliser and kelp powder.

The second round of treatment was applied on December 20, 2019, with the addition of S.O.A, sugar, molasses, lime flour and yeast, and replacing kelp powder with kelp flour.

The third round was applied at the end of March 2020 with the removal of the S.O.A and lime flour, and the addition of trace elements boron and cobalt.

Finally, round four was applied in mid-June 2020, adding SOA back into the mix to build feed going through winter to early spring.

Terragen Mylo, a microbial livestock feed supplement, was also fed to the cows on the home farm

“After the first application of Great Land, we saw a response within 10 days,” says Alan.

“We started with around 10 per cent clover, but it multiplied quickly; clover now makes up around 70 per cent of the pasture sward, and it is up there competing with the ryegrass.

“This is what we want to see as not only is clover extremely palatable to cows, but it fixes the nitrogen from the atmosphere naturally, decreasing the rate at which we will need to apply synthetic nitrogen.”

Despite the drought conditions last season, the home farm “hung on” far better than previous years.

“We had never seen the farm grow grass like that,” says Alan.

“Traditionally, we would feed out

Coast & Country

Cameron Law moves the herd into a stand-off paddock on his Whakatane dairy farm.

additional PKE to fill feed deficits, but last year we didn’t feed any at all until May when farm pasture covers were dropping due to lack of rain.”

Milk production reflected the substantial feed available: in early summer the farm was producing 100kgMS/day more than the previous season, and in April 2020 the herd was still producing 1.5kgMS/cow/day.

But perhaps most exciting of all was the reduction of synthetic nitrogen by 60 per cent.

Last season only 70 units of N was applied, but Alan says the response was comparable to a far greater application because the biology in the soil was better.

Only the beginning Alan says the results they’ve seen so far have exceeded their expectations.

“We thought we might be able to cut back nitrogen by 40 per cent, but to have achieved 60 per cent in a drought

The herd was still averaging 1.5kgMS/ cow in April 2020. year is quite astounding really.”

Alan says from the beginning, the Total Replacement Therapy team and the scientists involved reassured his family they weren’t taking a risk.

“They also didn’t pressure us with a ‘pureist’ concept from the start, and it has encouraged us to aim for even less nitrogen and better pasture this season,” says Alan. “The transition needed to be smooth for us to be comfortable.”

Alan is certain this way of farming is the best way to ensure the farm is successful for future generations.

“Succession farming was a big consideration when we decided to go on this journey because this land has been in the Law family for 100 years and we have a real sense of belonging here,” says Alan.

“Total Replacement Therapy has given our family a whole new concept of farming sustainably, and I think that’s going to be the future of farming in New Zealand.

“We’ve only just started to see the benefits.”

PH 07 578 0030

LAW

Page 57

LOCHLEA PARTNERSHIP

Page 58

MacKenzie Dyer

Coast & Country

milking system

Old system with milk receiving can and sanitary trap.

If the milking system is the heart of the cowshed, it’s certainly an investment worth getting right.

As the overseer for several Lochlea Partnership farms, Scott Evans knew the replacement of one of the farm’s milking systems had to be high quality, with hassle-free installation.

The farm in question was Lochlea’s Oxford farm, a 50-minute drive inland from central city Christchurch. Five staff were milking 1150 cows in a 50-bail rotary shed.

“I worked in that shed when things were breaking down every day, which interrupts milking and wastes heaps of time,” says Scott.

“We’ve learned the value of getting a regular service and keeping up with upgrades when we need them, to keep the farm running as efficiently as possible.”

Lochlea’s new milking machine is a Waikato

Milking Systems product – a Kiwi brand with a global reputation.

The Lochlea Partnership already had Waikato Milking Systems’ products throughout several of their farms, which made following suit with the Oxford farm’s milking system an easy choice.

The installation was completed by Morrison Agri at the end of the 2019 season.

Local specialists Morrison Agri has been supplying and servicing central Canterbury farms for 14 years.

The business specialises in Waikato Milking Systems’ products, and to date, they’ve installed more than 100 Waikato Milking Systems setups.

Morrison Agri do regular servicing for Lochlea sheds. “I don’t like downtime on the farm, so I’m very straight up about needing a quote, timeline and date sorted from the offset,” says Scott.

After.

“Morrison Agri is good at accommodating this, and getting the job done.”

The upgrade brought a 1990s green plastic milking system into a sleek, stainless steel future.

The stark difference between the two makes sense, considering the original milking system was installed more than 20 years ago.

A three inch milk line was replaced by a four inch line – a small expansion equalling significant benefit.

“A smaller milk line can hold up the milking by causing fluctuations that make the cows uncomfortable. They need to be in a relaxed state in their mind and body to produce high quality milk.”

As well as having significantly less maintenance to do on a new system, the biggest benefit of the upgrade is milk flow, says Morrison Agri’s operations manager for North Canterbury, Martin Saunders.

“Bigger lines and better joins means improved milk flow, no air leaks and overall less hassle,” says Martin.

“Even the smallest improvements to functionality in the shed can make a big difference – especially when you have lots of cows to milk like on Lochlea’s Oxford farm.

“The milking system really is the heart of the shed, so it’s incredibly important for it to be set up in a way that allows it to run as efficiently as possible.”

The size of the new milk receiver cans has been increased, to assist efficiency even further.

The upgrade included a new pulsation line, sanitary trap and a tidy-up of stray rubber from the old system, completing a design that is both modern in functionality and looks.

Two-week turnaround The entire process, from removing the old milking system of taking measurements and installation, only took a couple of weeks.

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Matthew Paton Craig Direen Senior Agronomist/ Assistant Gerard Dawson Kelvin Mansfield Agronomist Manager B.Ag B.AgSc Key Acct Manager Manager Matthew Paton Craig Direen 027 544 1171 021 109 1087 Senior Agronomist/ Assistant Gerard Kelvin Mansfield 027 443 Agronomist Manager 03 434Dawson 7766 B.Ag4701 Matthew CraigB.AgSc Direen Key AcctPaton Manager Manager Gerard Dawson Kelvin Mansfield 027 544 1171 021B.AgSc 109 1087 Senior Agronomist/ B.Ag Assistant 027 443 4701 Agronomist Manager 434 7766 PROUD03Manager TO HAVE SPONSORED OUR LOCAL SCHOOLS Key Acct Manager Senior Agronomist/ Assistant 027 544 1171 TO HAVE 021 109 1087 Agronomist Manager PROUD SPONSORED OUR LOCAL SCHOOLS 4701 Acct443 Manager 03Manager 434 7766 027 544 1171 021 109 1087 AGAIN THIS YEAR - THROUGH YOU. Key027 Agronomist Nick Walters Agronomist 027 244 4057 027 244 4057 Agronomist Nick Walters Agronomist 027 244 4057 Nick Walters 027 244 4057 Agronomist Agronomist 027 244 4057 Agronomist 027 244 4057 Agronomist 027 244 4057 027 244 4057

THIS YEARS RESULTS 03 434THIS 7766 AGAIN YEAR - THROUGH YOU.

Waitaki Valley School

THIS YEARSOmarama RESULTS $682.00 School THIS YEARSWeston RESULTS $682.00 Omarama School $1026.25 School THIS YEARS RESULTS

027 443 4701

$1514.85

Waitaki Valley School $1514.85 Duntroon School $467.00 Waitaki Valley School $682.00 Omarama School $1514.85 Duntroon School $1026.25 Weston School $467.00 Papakaio School $938.00 St Josephs School $530.00 Waitaki Valley School $682.00 Omarama School $1514.85 Duntroon School $1026.25 Weston School $467.00 Papakaio School $938.00 St Josephs School $530.00 Five Forks School $507.00 MahenoSchool School $235.00 Duntroon School $1026.25 Weston $467.00 Papakaio School $938.00 St Josephs School $530.00 Five Forks School $507.00 Maheno School $235.00 Glenavy School $1539.00 Total this Year $7440.10 Papakaio School $938.00 St Josephs School $530.00 Matthew Paton Craig Direen Gerard Dawson Kelvin Mansfield Nick WaltersCraig Direen B.Ag B.AgSc Matthew Paton FiveMansfield Forks School $507.00 Maheno School $235.00 Gerard Dawson $1539.00 Kelvin Nick WaltersTotal Glenavy School this Year $7440.10 B.Ag B.AgSc Five Forks School $507.00 Maheno School $235.00 Agronomist Senior Agronomist/ Total donation the Assistant past 3 years $12,856.60 to the local schools in Agronomist/ the region.

Agronomist Agronomist Manager over Agronomist Senior Assistant 027Total 244 4057 Key Acct Manager Glenavy School $1539.00 this Year 021 109 1087 $7440.10 Agronomist Agronomist Manager 027Total 244 4057 027 544 1171 Manager Manager 027 244 4057 Key Acct$7440.10 Manager Glenavy School $1539.00 this Year 443 4701 Total donation over the03 past 3 years $12,856.60 to021 the region.

434 7766 027 244 4057 027 544 1171 109local 1087 schools in the 027 03 434 7766

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Total donation over the past 3 years $12,856.60 to the local schools in the region.

Total donation over the pastYOUR 3 years PASTURE, $12,856.60 to COME the local schools in theTEAM region.

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THIS YEARS RESULTS WHEN RENEWING YOUR PASTURE, COME SEE THE TEAM AT NORTH OTAGO PASTORAL SERVICES THIS YEARS RESULTS WHEN PASTURE, COME SEETHE THETEAM TEAM Waitaki RENEWING Valley $682.00 Omarama School $1514.85 AT School NORTHYOUR OTAGO PASTORAL SERVICES WHEN RENEWING YOUR PASTURE, COME SEE Waitaki Valley School $682.00 Omarama School $1514.85 AT NORTH PASTORAL SERVICES 3 Usk St, OamaruOTAGO 9400 | www.nops.co.nz | 03 434 7766 Duntroon School $1026.25 Weston School $467.00 AT NORTH OTAGO PASTORAL SERVICES Duntroon School $1026.25 Weston School $467.00

3 Usk St, Oamaru 9400$938.00 | www.nops.co.nz 03 434 7766 Papakaio School St Josephs| School $530.00 Papakaio School $938.00 St Josephs School $530.00 3 Usk St, Oamaru 9400 | www.nops.co.nz | 03434 4347766 7766 3 Usk St, Oamaru 9400 | www.nops.co.nz | 03 Five Forks School $507.00 Maheno School $235.00 Five Forks School $507.00 Maheno School $235.00 Glenavy School $1539.00 Total this Year $7440.10 Glenavy School $1539.00 Total this Year $7440.10 Total donation over the past 3 years $12,856.60 to the local schools in the region.

Total donation over the past 3 years $12,856.60 to the local schools in the region.

PH 07 578 0030

Page 59

LOCHLEA PARTNERSHIP

After.

Before.

The old system with plastic pulsation line and 3-inch milk line.

The Morrison Agri van at Lochlea’s Oxford farm.

Martin says all Waikato Milking Systems’ milking systems are completely customisable, and can be made to fit any space – regardless of what system was used previously.

“While winter is the best time for a new installation, so the shed is ready to go for calving, we can be flexible and work within the farm’s schedule.

“Lochlea’s farm was a winter installation, but on other farms that do year-round milking there are things we can do, like working between 15-hour milkings. Farming can’t stop, so we work around it.”

As well as being customisable, milking machines by Waikato Milking Systems can easily have extra features added on at a later date, so farmers can update and improve their system when it suits them best.

“That’s one of the many benefits of working with Waikato Milking Systems products – because they are locally-developed, farmers can plan how they want to improve their farm over a long period of time.”

Waikato Milking Systems’ mastitis detector has been in use on the Lochlea farm for several years, but it’s impossible to tell by looking – even when it’s directly connected to the new milking system.

The SmartD-TECT mastitis detector has customisable sensitivity settings that can identify mastitis up to four days before symptoms begin to show.

“SmartD-TECT is the highest spec mastitis detector from Waikato Milking Systems,” says Martin.

“It’s an automated system that individually tests each teat for irregularities between them, accurately ensuring the farmer is informed of any issues.”

Easy-peasy automation SmartD-TECT connects to the shed’s Smart ECRs – Waikato Milking System’s trusty automatic cup remover for rotary sheds.

In doing so, the SmartD-TECT and Smart ECRs can control Waikato Milking System’s BailMate Rams.

The upgraded pulsation line and 4-inch milk line.

The BailMate strap doesn’t move if issues are flagged by SmartD-TECT, ensuring the cow stays on the platform so the farmer knows the cow needs assessing.

If no issues are detected, the cups are removed and the BailMate straps are raised, for the usual easy, automated milking.

Lochlea prioritise servicing to ensure they make informed decisions about where to invest their money – something Martin says he can’t recommend to farmers enough.

“Scott and the team are great at booking regular services, which is something we encourage all farmers to do to ensure milking carries on smoothly,” says Martin.

“Finding potential issues before they become major problems saves plenty of unnecessary stress, and keeps farmers’ investments ticking over for longer.”

Into the future While the Oxford farm has no further upgrades on the horizon just yet, Scott says they are always assessing what needs improving. “It’s about finding the balance between what’s best for efficiency, and what will just sink your money.

“A well running milking system is a necessity – and well worth the money spent.”

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ISLAND GLEN DAIRIES

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New dairy

Coast & Country

Clare Bayly

Island Glen Dairies’ farm business manager Nick Paul, with Rob Morris of Morrison Agri.

The Waikato Milking Systems’ SmartSPRAY automatic teat spray system ensures maximum coverage of the udder, regardless of cow position in the bail.

Rain on the day New Farm Dairies visited did not diminish the scale and practicality of the “good basic shed” built in 2009.

Attracting and retaining “the right people for the job” was a driving force behind the upgrade of a 54-bail rotary dairy at Rangitata Island in the South Island.

Island Glen Dairies is one of five Canterbury dairy farms owned by the Spectrum Group.

Formerly a sheep farm, the property was converted to dairying in 2009 and today milks 790 cows at peak on a milking platform of 200 hectares.

Farm business manager Nick Paul has managed the farm since 2016 and says the dairy, built in 2009, was “a good basic shed which lacked technology”.

“It was labour-intensive with no bail retention,

automatic cup removers or automatic teat spray – so we needed two people, one at cups-on and another at cups-off at each milking.

“Looking forward we could see staff issues; it’s getting harder to get good staff who are skilled workers and we wanted to upgrade the dairy to create an environment which would help us attract and retain the right people.

Productive potential “It had to be an environment you wanted to be in, which made good use of people skills and enabled the cows to fulfil their productive potential.”

Cup removers were top of the list because they would allow the farm to drop to one person in the dairy, says Nick. “They’d also mean that, if we were short-staffed during the

season, we could get away with two people on the farm instead of four.”

Nick says enhancing the dairy meant that the team of four could enjoy time off and sleep-ins on a regular basis – “elements which are vital to job satisfaction and family life; both elements the Spectrum Group values and encourages amongst its teams”.

Rob Morris of Morrison Agri was called in to advise them and says the opportunity to add automation “would significantly improve the dairy’s overall efficiency and productivity”.

Achieving this was relatively simple, with the installation of Waikato Milking Systems’ SmartECRs, BailGate Straps and SmartSPRAY automatic teat spray system.

“SmartECRs prevent over-milking and its associated impact on udder health and incidences of mastitis,” says Rob.

“Clever software in the SmartECR caters for an almost limitless array of milking routine parameters, enabling farmers to tailor a variety of settings to suit herd and individual preferences.”

Software sharing Rob says SmartECRs also work with Waikato Milking Systems’ flow sensor technology.

“Together they provide accurate end-of-milking identification and minimal vacuum drop during milking. The sensor triggers the end of milking and blocks the vacuum to the cluster prior to the clusters being removed.

“SmartSPRAY is Waikato Milking Systems’ automatic teat spray system designed specifically for rotary dairies, replacing the need for manual teat spraying and dipping.

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ISLAND GLEN DAIRIES

SmartECRs work with Waikato Milking Systems’ flow sensor technology. Together they provide accurate end-of-milking identification, triggering the SmartSPRAY and BailGate Straps.

“The system ensures maximum coverage of the udder regardless of the cow’s position in the bail.” SmartSPRAY is initiated by the SmartECRS to spray soon after the clusters have been removed, ensuring the udder is sprayed while the teat orifice is still open. No operator input is required during milking other than filling the tank with teat spray every few days.

Rob says the raising and lowering of the BailGate Straps is triggered by the SmartECRs at the start and end of milking. “In the event of a cluster being kicked off during milking, an alarm occurs and the BailGate Strap remains in place enabling the reapplication of the cluster at the cups on position,” says Rob.

Seasonal timing Timed for winter 2019, the retrofit occupied a total of four weeks. “Equipping the dairy to take the BailGate Straps and SmartECRs called for a mounting bracket,” says Rob. “It took around five days to engineer and install bail

The addition of Waikato Milking Systems’ SmartECRs, BailGate Straps and SmartSPRAY has not compromised the dairy’s uncluttered interior.

posts and a top ring around the inner side of the bails onto which the BailGate Straps and SmartECRs were attached.”

Looking back on the first full season in the enhanced dairy, Nick says it all worked from day one. “There were no issues right from the start.

“I’ve worked in other sheds and this is the easiest I have worked in by far. It has transformed milking.

“The upgraded dairy has saved us not hiring the wrong people. We have been short-staffed most of the season but, where before that might have put us under pressure, the increased efficiency and simplicity of the dairy meant that efficiency wasn’t compromised.

“The addition of cup removers took a lot of pressure off and gave us the luxury of taking the time to find the right person for the job, rather than hiring someone who was available but who didn’t have the specific skills we require.”

Nick says before cup removers they needed

two people in the shed with another person bringing the next mob in “but now we have one person milking and one person getting the cows in”.

“We’ve effectively freed up a labour unit to either rest and relax or attend to other jobs on the farm. The dairy upgrade has had a significant impact on the overall efficiency of the farm,” says Nick.

“We have less cases of mastitis than we’d normally have because cows are being milked out and receiving teat spray at the optimum time.”

Mastitis cases down To be effective, teat spray needs to be applied within 20 seconds of the cluster being removed. “Teat spraying in the original setup was manual, meaning that if the cups had been kicked off half-way round the platform, the teat canal could have been closed when

Page 61

The dairy is now not only spacious and light-filled but efficient, creating a great working environment. teat spray was applied at cups off,” says Nick.

“Now, the Waikato Milking Systems’ teat spray is activated at a preset time within 15 seconds of the clusters retracting. As a result, cases of mastitis have decreased and our average Somatic Cell Count is significantly less than it used to be.

“We’re milking longer because cows are being milked out now, animal health is better and we’re spending less on mastitis treatment.”

The improved efficiency of the new rotary has impacted on the amount of annual leave the farm would normally have to carry over too.

“Carrying over annual leave is a significant cost for any business and it’s a sad reality on many dairy farms. The improved efficiency of the new dairy, however, means our people can now take time off during the season with the result we’re not carrying over so much annual leave.

“That’s a win-win for the business and for our team and their families,” says Nick.

KAHERA LANDS

Page 62

Coast & Country

Three herds Bridget Jochems

Father-andson Maurice and Phillip Eccles made a great team on their new dairy project.

The new 50-aside herringbone milking shed.

Maurice and Fay Eccles have been dairy farming the majority of their working lives. Their son Phillip Eccles now contract milks 700plus cows on their 225ha Hauraki Plains farm, through a new 50-aside herringbone cowshed.

Maurice and Fay bought the central 70ha part of this farm 30 years ago. Today the farm is made up of four blocks of land, as they purchased more land to the east, north and south of their original block. The new shed has consolidated these four blocks of land into one coherent dairy farming unit.

One of the original cowsheds that was milked in up until the end of the 2018/2019 season.

“Despite the fact that I didn’t want to spend lots of money on a new shed and would have rather spent it on a new boat, I think that you have to listen to the younger generation of dairy farmers and Phillip was right, the new shed has consolidated the dairy operation well,” says Maurice.

Farm labour is divided with Maurice rearing 150 replacement calves and grazing 150 replacement heifers on a runoff block, Phillip is in charge of day-to-day running of the farm and he employes a farm manager and a farm worker.

“Up until June 2019 we were milking through a 22-aside herringbone, a 24-aside herringbone and an 11-aside herringbone shed,”

says Phillip. “I was milking in the 11-aside and relief milking in the other sheds as required, so I was very keen to streamline the operation.”

Shed tour Deciding on what sort of shed to build wasn’t too difficult for the Eccles. Builder Shanan White, from Don Chapman Waikato Ltd, took Maurice and Phillip out for the day to look at sheds that had been designed by Chapman Dairy in Morrinsville and his company had built in the area.

“This was a good way for us to do research, we spoke to the farmers and found out what worked well. A shed in Te Kauwhata looked ideal for what we needed. We pretty much

followed that design exactly,” says Maurice.

The shed includes a toilet, records room, plant room and a separate room for the vacuum and farm water pumps. Cladding is insulated panel for the walls and roofs of the operational area and the roof for the pit area is Zincalume.

The 50-aside herringbone has cup removers, but the Eccles didn’t want a meal feeder system put in as they are mainly grass farmers.

“Identifying a building site on the Hauraki Plains can be challenging,” says Shanan. “The soil is predominantly peat and it is much easier to build the shed and effluent disposal system in the clay area. Fortunately, there was a small clay hill on the Eccles farm that after a bit of earthworks was the ideal site for the shed.”

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KAHERA LANDS

L to R: Williams Irrigation’s Brook Evans, LIC’s Jason Quertier, Dave Gray of DTS, Ngatea Milking Machines & Pump Services Ltd’s Wayne Barker, farmers Phillip Eccles and his father Maurice Eccles.

Maurice was told with a 50-aside herringbone, cup removers are an essential component. “Initially I wasn’t keen on them.

On the first farm that we owned, we took the cup removers out as they often took cups off before cows had finished milking.

“Phillip and Wayne Barker from Ngatea Milking Machines & Pump Services Ltd convinced me that they have improved dramatically since then and they have worked really well. It means that after AB it only takes two people to milk 700 cows.”

Two entrances As the new shed is built on a new site, just down from the original 22-aside herringbone, the other sheds were able to be used until the new complex was completed. Construction started in February 2019 and was completed in

time for the first cows to calve in June 2019.

“We still run the cows in three herds, so they are not standing around waiting too long and although we’ve got a new shed, we did not have to change the rest of the farm’s infrastructure,” says Phillip. “We have three separate farm water supplies and we made minimal changes to the fencing.”

The farm is mainly flat and at worst cows have a 1.5km flat walk to the shed. The shed has been designed with two entrances so two herds can be taken to the shed at the same time, then one person will start milking while the other person will go and get the third herd.

“We chose Ngatea Milking Machines & Pump Services Ltd to outfit the shed with the milking plant for us,” says Maurice. Ngatea Milking Machines & Pump Services Ltd has a team of people that work on all different aspects of

dairy shed installations – for example, milking systems, water systems and effluent.

Wayne Barker from Ngatea Milking Machines & Pump Services Ltd has done a number of installs with builder Don Chapman Ltd, along with local electricians so has good working relationships to ensure projects come in on price and time.

DeLaval’s Waikato district sales manager Malcolm Kensington says the DeLaval plant is a 50 unit MidiLine 2100 with MPC150 cluster removers with Comfort Start, it has a LVP4500 Lobe Vacuum Pump, which is controlled by a variable speed drive which can save up to 70 per cent in power.

“The plant has a 100mm milkline connected to a 100L receiver. The milk pump is a 2.2kW, which is controlled by a variable speed drive to optimise milk flow and therefore

assist with milk cooling.

“The milk filter will filter milk for up to 880 cows. The industrial plate heat exchanger has two banks; the first is for pre-cooling, and the second one has iced water passed through to bring the milk temperature down,” says Malcolm.

Drafting asset Another addition that Phillip knew would be an asset to the shed and the whole farming operation was the Protrack Vector Drafting unit, which integrates directly to MINDA LIVE. “This is really efficient and a real timesaver,” says Phillip. “The cows walk through it after every milking and each time their tag is read, we always know exactly how many cows we have milked and so know straight away if one has been left in the paddock.”

KAHERA LANDS

Page 64

Williams Irrigation’s Brook Evans and farmer Phillip Eccles in the sump.

Dave Gray of DTS with the DTS 15hp water cooling unit – a good choice for such a big herd.

Ngatea Milking Machines & Pump Services Ltd’s Wayne Barker in the milkroom.

The LIC Vector 2G Drafting Unit.

This farm is using also automation with Protrack, including Protrack Draft, says LIC national product and sales manager Jason Quertier.

“This saves farmers lots of time and they are much safer than pulling a string to open a gate, jamming the cow into the gate, losing her and then running down the race to get her back.

“Farmers are able to load which cows they want sorted into MINDA LIVE on their computer or their phone; and after milking, when the sensor reads her tag, the drafting unit will open the appropriate gate,” says Jason.

It also possible to draft from the farm pit using the Pit PC and this is ideal for when on-heat cows are noticed during milking, and it can also be operated with a remote.

“It’s a great system that can have other features added to it, if farmers require, such as an automated heat detection Protrack Heat

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unit that will identify which cows are on heat and a Body Condition Score camera called Protrack BCS, so it is easy to track if animals are gaining or losing weight,” says Jason.

One big advantage with milking out of a single shed is having all the effluent managed with one machine at one site.

Total effluent con ol The Eccles were able to keep the in-paddock part of their effluent irrigation system, but a new pond was built with a new sump and pumping system. Brook Evans from Williams Irrigation in Ngatea was responsible for working out what system would work best for the Eccles.

“As the effluent pond is uphill from the sump, it is necessary to have a pump in the sump to move the effluent to the pond – and it is only

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Coast & Country

Farmer Phillip Eccles and LIC’s Jason Quertier discussing the keypad that milkers can use in the pit to operate the drafting unit.

necessary to do this when it is not ideal to pump the effluent directly onto the pasture,” says Brook.

“So, for example, if the ground is wet the effluent is pumped into the pond and then is gravity fed back into the sump for when it is a good time to spread the effluent onto the pastures. This gives total control of where the effluent goes and when it goes there.”

Brook says this system is made to order “and in this case there are two pumps in the sump; one to pump effluent up to the settlement pond and one to pump it to the irrigation system”.

The 40m by 30m by 4m effluent pond is lined with a 1.5mm HDPE high-density polyethylene synthetic liner which includes a geotextile layer and gas venting system supplied and installed by Karl Hogan from Agruline.

It is complete with safety access ladders should anyone find themselves in the pond and

needing to get out. “That should never happen though as our effluent system does not require a pump in the effluent pond,” says Phillip.

Dairy Technology Services’ refrigeration engineer and Waikato area sales manager Dave Gray says refrigeration for such a big dairy operation had to be well thought-out.

“Because there are up to 750 cows being milked daily there is a limited amount of time in-between milkings for the water in the insulated 30,000L water tank to be cooled again in time for the next milking.

“So Maurice decided on the DTS 15hp water cooling unit that chills the water down to seven degrees Celsius before it goes into the tank.

“This then chills milk going into the vat down to 10 degrees Celsius and with the vat refrigeration unit the milk is then further cooled down to five degrees Celsius before it is picked up by the tanker – even if the tanker arrives straight after milking,” says Dave.

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KAHERA LANDS

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Page 66

BASSETT FARMS

Coast & Country

Futureproofing

home MacKenzie Dyer

Rob Bassett operates the stirrer, with people involved in the effluent project watching on.

Waikato Milking System’s Ben Frederickson, Ordish & Stevens’ Brian Deller, and farm owner Rob Bassett at the pond.

Rob Bassett has witnessed plenty of upgrades on Bassett farms in Carterton – he grew up there, and the land has been in his family since 1911.

Between three generations of Bassett farmers, what was once 70ha of tree stump-covered land in World War 1 New Zealand, is now a high producing 100ha farming platform with a 120ha runoff.

Rob and his wife Nicola have owned the farm since 2007.

Their latest addition: a Waikato Milking Systems effluent system, was completed last year.

Bassett Farms went from having no effluent storage at all, to a lined holding pond that can store up to 6.5million litres of effluent – more than enough space for their 450 pedigree Friesian cows.

Effluent is scraped off the Bassett’s feed pad about once a week into a concrete storage bunker.

A stone trap catches grit from cows’ hooves before entering the feed pad, protecting the effluent system’s pumps and equipment from wear and tear. The storage sump at the end of the bunker collects the liquid effluent.

From there, a 25hp Doda long shaft pump transfers the

effluent, either to be dispersed through the King Cobra Travelling Raingun, or to be stored in the pond for later use.

A horizontal stirrer keeps crusts and sediment from forming inside the pond. The stirrer can easily be winched out of the pond and rotated onto the bank, making for easy and safe servicing.

A mono pump transfers effluent to irrigation systems around the property.

Simple storage Rob and Nicola’s priority when choosing an effluent system was to keep it simple. “There were plenty of add-on options, but for us it’s about minimising breakdowns by having less mechanical parts.”

This was well understood by Brian Deller from Masterton-based business Ordish & Stevens, which specialises in rural infrastructure and design. Brian consulted with the couple throughout the project, and the business completed all of the required electrical and fitting work.

The effluent pond.

“The more complicated you get, the higher the risk of blockages, breakages, malfunctioning valves – that sort of thing,” says Brian.

“The simplicity of Rob and Nicola’s system has proven very practical. In the year or so it’s been operating, it hasn’t needed much more than a squirt of grease.”

The process was completed in separate stages over three seasons. Added up, the entire effluent system, from earthworks to completion, took just over two months to complete.

A long time coming Rob and Nicola have wanted to upgrade their effluent system for about a decade. “It just makes sense,” says Rob. “The effluent pond holds about 150 days’ worth of storage, so we only need to deal with it when we actually need the effluent.

“Before, we had to spread effluent every day. Most of our farm is a naturally-draining swamp, so spreading in spring with a high water table wasn’t ideal.”

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BASSETT FARMS

The storage sump from the feed pad.

Rob Bassett is the third generation to run the family farm at Carterton.

The sump under construction.

“We were running just to keep up with any regulations. While we still had two years left on our effluent consent with the Wellington Regional Council in 2017, we thought we may as well get ahead, and started the upgrade in 2018.”

Despite the long wait, the timing was ideal.

In 2016, the Bassetts bought land from a neighbouring farm, and its lighter soil type was a much better foundation for an effluent pond, allowing it to sit half in the ground, and half above.

Loyal customer For Rob and Nicola, choosing Ordish & Stevens for the project was a no-brainer – Brian has been working with the Bassett farm for 40 years. “Brian was Dad’s go-to man for many years

Rob and Nicola Bassett’s sons Campbell and Lachie in the lined holding pond that can store up to 6.5million litres of effluent.

– I’ve known him since I was a kid,” says Rob. “He’s been my point of contact throughout the process, as a mentor and a sounding board to double check things with.

“Because we’ve worked with Ordish & Stevens for so long, we know everyone on a first name basis and know who to call for different jobs. It’s incredibly efficient – they’re always on the ball and very responsive,” says Rob, who states: “I don’t go with the brand, I go with the people”.

In saying that, Rob and Nicola couldn’t be happier with the quality of Waikato Milking Systems’ products. “We can’t fault the products, really. Waikato Milking Systems’ representatives visited the farm throughout the process and made sure it was all going smoothly,” says Rob. Waikato Milking Systems lower North Island sales and services manager Ben Frederickson says being present is a priority for all reps.

“Like myself, many Waikato Systems representatives usually come from a farming background, so we know the importance of checking in and ensuring the farmers get what they need,” says Ben.

No place like home Having an effluent pond that can store more than what they need was an intentional move by Rob and Nicola to futureproof their investment.

It may turn out to be more than just a business investment – Rob and Nicola’s sons Campbell, 12, and Lachie, 10, already seem keen to be the fourth generation of Bassetts to work the farm.

“I can’t tell them what I’m doing on the farm on a particular day, because they’ll try to pull a

sickie from school so they can come and help – that’s how much they love it out here,” says Rob. “It’s really special to watch them grow up on the farm and enjoy it like I did. I moved away for six years to study and travel, which makes you really appreciate where you’re from.”

Rob says returning to the family farm isn’t uncommon in Carterton. His sons go to school with kids of several friends he grew up with, who all stayed farming in the area.

Brian can attest to that – numerous farms he works with throughout the Wairarapa area are run by the second or third generation of family members.

Nicola isn’t far from home either, she grew up in Carterton town. For locals in the tightknit community, there seems to be no place like home. “That’s how my Dad feels, too,” says Rob. “He still lives across the road.”

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LONGRIDGE

Page 68

Coast & Country

expectations Clare Bayly

The term ‘function and form’ is more often associated with residential and commercial architecture than it is of agricultural buildings – but it is an apt description for a remarkable new dairy on Longridge Farm south of Te Awamutu.

Seen from afar the dairy presents as a streamlined, curved-roofed building clad in exposed aggregate concrete panels, the impression of ‘something different’ only increasing upon closer inspection.

While visually impressive, this is a working environment that challenges the traditional image of ‘a cowshed’ – spacious and pristine with state-of-the art technology minus the sight and aroma of dairy effluent.

Third generation Mark Sanson is the third generation of his family to farm the property. He, wife Jann and stepson Mitch Pound now farm the property Mark’s grandfather originally acquired.

“Back then the farm comprised of 84 hectares, my grandfather added a neighbouring block when it came on the market. We have continued to purchase further land and today the milking platform comprises around 190 hectares,” says Mark.

The property has seen “a few dairies”, culminating in a 30-bail rotary built in 2001.

Mark says it was a pretty basic shed but was adequate for the herd they were milking then.

“Traditionally, our herd genetics were sourced

The pit is a talking point with blue-andwhite rubber tile flooring.

The heavy duty pipework, designed and built by DairyTech, which features throughout the dairy.

Cow health, performance and feeding levels are on display with the DelPro herd management system. from New Zealand but, wanting a largerframed Holstein capable of higher production, we progressively began using overseas sires.

“Increased cow liveweight had an operational impact in the shed, however; the bails were too narrow for the larger cows and the rubbers would often catch as they backed off the platform.

“We considered all the options for providing a more comfortable and efficient environment for the cows and operators and this eventually led to the realisation that the most effective way to resolve the issues we were experiencing was to build a new dairy.”

Initially Mark and his family considered

building another rotary with a larger platform and wide bails to provide the comfort the herd needed.

Rapid exit parallels “But my stepson, Mitch, had just arrived home from working in the United States. He had worked on a number of farms and said there was a lot of talk about large-scale 24-hour operations replacing their rotaries with rapid exit parallels to improve throughput, cow comfort and efficiency.”

In essence, a rapid exit parallel is similar to a herringbone in that 24 cows walk down a row that is parallel to the pit. The difference is that, as each cow reaches her position, she turns

three-quarters and triggers a head bail, which positions her over an individual feed bin. At the end of milking, instead of the row filing out as they would in a herringbone, the entire bail system lifts by air vacuum, enabling the cows to simply step out and exit the dairy.

Longridge Farm milks year-round, with calvings in autumn and spring under a 4 or 5 farm system. The herd is milked in two mobs, each spending time, before or after milking, on a feed pad that was adjacent to the old rotary.

Satisfied that a rapid exit parallel would provide the optimum environment for the herd, Mark and Jann called in Peter Gray of Otorohanga-based Dairy Tech to design and build the new dairy.

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The view from the office in the new dairy.

Some of the team who contributed to the build: Zakk Pratt, Mitch Pound, Aaron Murphy, De Laval herd management specialist Samantha Kietzman, and Mark Sanson.

Farmer Mark Sanson and stepson Mitch Pound with one of the farm’s central characters, a chocolate Labrador named ‘Bear’.

Farmer Mark Sanson demonstrates the ease of changing a milk filter in the new dairy.

Peter says Dairy Tech has been providing design solutions and construction integrity for farm dairies since 1985. “And it’s fair to say the sophistication of those demands has increased in line with the growing emphasis on environmental sustainability.”

Peter says the design of this new dairy was the result of a number of meetings with Mark, Jann and Mitch “to understand the environment they wanted to create for their high-producing herd, and the people who would work in the dairy”.

Low maintenance “The construction of the Longridge dairy features pre-cast concrete panels, exposed aggregate on the exterior, with polished interior, combining durability with reduced maintenance. “Dairy Tech designed,

The exterior of the precast concrete cladding features exposed aggregate. manufactured and installed the panels along with the curved truss roof, which features bird-proof rafters.

The dairy features a range of support rooms – a machinery room, a switchboard room raised above the floor level to provide a waterfree environment, and an office/staff room with a large viewing window over the milking environment.

“Dairy Tech designed, manufactured and installed all of the yard pipework, which includes the collection yard capable of holding around 250 large-framed Holsteins, a 20-animal vet race and AB facilities.”

Peter says the new dairy had to provide the optimum environment to enable Mark’s genetics to realise their potential “and working with DeLaval and Pratt Milking Limited, we’ve achieved that”.

The streamlined Longridge dairy features a curved roof and exposed aggregate walls.

Pratt Milking Ltd director Zakk Pratt says the DeLaval P2100 24-aside Rapid Exit Double-up Low Line dairy provides a level of technology absent in the retired rotary.

“It has all the bells and whistles to optimise every aspect of milking from individual animal ID, through to milk meters and yield indicators that measure the individual cow and herd’s dayto-day production, electronic cluster removers and automated individual feeding.”

Real time info The DelPro Herd Management system accurately identifies each cow as her ear tag is triggered in the head bail. Milk meters record and provide the operator with real time insight to production at each milking with seven-day averages available at the touch of a finger. The ICAR approved DeLaval

milk meter MM27BC delivers accurate data on milk flow, milk yield plus will identify whether there is blood in the milk.

Zakk says targeted feeding is enabled by the DeLaval Feeder, which delivers any calibrated volume of concentrates – either blanketed or for individual cows, to maintain their milking performance. “The system is capable of blending up to four separate feeds, dispensing the right mix and content of feed to each cow according to a range of parameters including age, production and liveweight.”

Three-way drafting is provided by the DeLaval DSG3 drafting gate, which sorts cows into their respective group or enables precise selection without interrupting cow flow. Drafts can be preset ahead of milking via phone app or PC, or as required during milking.

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The 250-cow collection yard features a High Runner Backing Gate, which complements the yard floodwash.

The vet race, capable of holding up to 20 Holsteins.

“Latest technologies with lighting and electricity usage are employed with LED lighting and variable drive technology. There is also provision to add a generator to provide operational certainty. Vacuum is provided by the LVP 4500 vacuum system with pushbutton cleaning thanks to the C200 automatic plant wash,” says Zakk.

Talking point “The wide pit is a talking point for any visitors to the dairy with blue-and-white rubber tile flooring and an effluent-free environment thanks to an effluent tray, which catches urine and dung ‘as it happens’. Automated wash of the effluent tray and floor is triggered each time the bails rise to exit the cows.”

The High Runner Backing Gate from Michael Bloemen Engineering of Taranaki complements the collection yard floodwash.

Looking down the row towards the entrance clearly show the head bails, which trigger as each cow positions herself over the feed bin.

Three-way drafting is provided by the DeLaval DSG3 drafting gate.

The efficiency of the yard and effluent tray wash, after each row is released, mean an effluent-free milking environment for milkers.

The gate’s unique self-aligning system reduces wear and tear and enhances the life of the system minimising gate breakdowns. The gate’s high clearance is ideal for the two-herd system operated on Longridge Farm.

To maintain efficiency and optimise farm services and layout, Mark and Jann decided the new dairy’s yards would extend from the feed pad.

The Sansons prepared the site of the new dairy and construction commenced in February 2019 with the new dairy commissioned seven months later in August.

“We weren’t under any pressure to complete the new dairy as the old shed, while too small, was still functional,” says Mark.

Looking back, he recalls that transitioning the cows from the rotary to the parallel was a challenge which took “six-and-a-half hours in the first milking”.

“The cows were used to stepping onto the

Coast & Country

rotary platform. In the new parallel they had to walk down the row and then do a threequarter turn to trigger the head bail over the feed bin. And then, at the end of milking, the feed bin would quietly rise leaving them with an open space to step into. It was a huge change for them, but we’d allowed for that.

“We were thankful to have a quiet herd as it took two people to guide each cow into position during those first few milkings.

Superb job “Training the cows was a real team effort and Jann and I are so grateful to the guys who’d worked with us on the dairy – Pratts, DeLaval etc – because they were all on-hand to help us transition the cows to their new environment.”

Mark says day-by-day the cows became more

The bails, with feed bins, lift at the end of milking enabling the cows to step out and exit the dairy. accustomed to the new environment – the feed helped – and after a couple of weeks they happily walked on by themselves.

“From day one, the dairy has performed beyond expectations. You always expect to have a few teething issues but we’ve had none.

The construction and installation teams did a superb job – this shed does what it’s meant to do – and more – and the cows and milkers couldn’t be happier.”

Mark says the benefits of the advanced technology is already delivering tangible savings with tailored feeding enabling a 10 per cent increase in production, and a decrease in feed costs of 20 per cent.

“One person can easily milk each mob with another getting the herd onto the feed pad or into the dairy. It’s a dairy anyone could operate – simple, efficient and an absolute pleasure to milk in.”

PH 07 578 0030

LONGRIDGE

Page 71

Page 72

UDDERLEY FARMING

A rewarding Clare Bayly

Debbie Wellman checks on the 400cow herd at the end of their break on the feed pad.

The original dairy was old but sound and had “great flow”.

Debbie and Shanan Wellman with the sign they brought with them from the Waikato.

In a little over 21 years Shanan and Debbie Wellman have determinedly moved “through the grades” – starting off on wages and then progressing through sharemilking until they finally achieved farm ownership in 2016.

“We both grew up in town but always wanted to be dairy farmers so we just got our heads down and started working,” says Debbie.

“Farm ownership was always the goal and, after a few years 50/50 sharemilking in the Waikato, we began to seriously look for a farm we could afford. We cast the net wide but had to consult a map when a suitable farm came up in Rai Valley – at the top of the South Island near Nelson – as we’d never heard of the area.”

That all seems a long time ago. Shanan and Debbie purchased the 160 hectare property and moved their family and herd of 400 Friesian crossbred cows to the farm ready for the start of the 2017 season.

“We kept around 100 heifers and some of the older cows from our original herd and purchased the rest of the cows from the North Island, trucking them south. The cows transitioned well, recording an average 480kgms in the 2019/2020 season,” says Shanan.

The couple recall the ‘new’ farm had an old 44-bail rotary shed, which was sound but inefficient.

“We milked in it for the first season and while it had awesome flow it was very labour-intensive with heavy clusters, which were constantly falling off, cup removers which didn’t work and no bail restraints.

The dairy has an abundance of natural light and space around the platform.

“Having to apply chains to keep the cows on the platform, combined with cup slippage, meant we needed two people in the shed. We managed through that first season, with multiple breakdowns, but knew we’d have to make some improvements for the following season,” says Shanan.

“The basic structure of the shed and platform were sound, we just needed to make it simpler and more efficient.”

Dairy upgrade After going on-farm to carry out an inspection of the Wellman’s current milking system, Aaron Potter of AG Water Ltd recommended they upgrade the dairy to something more reliable and efficient.

Aaron recommended retrofitting GEA Intel-

ligent Cluster Removers (iCR), which control the GEA iCRS Cow Restraint System. He also recommended replacing the old, heavy clusters with GEA iC330 clusters, which have 330ml capacity yet only weigh 600 grams.

GEA area sales manager David Jones says GEA Farm Technologies is “innovative engineering, manufactured in New Zealand and designed for pastoral dairy farming”.

“It’s simple and reliable, backed by the research and development of one of the largest milking systems organisations in the world.

“The iCR cluster removers contain features usually found in high-end systems – for example, the kick off sensor, fully adjustable settings using a handheld programmer – but at an affordable price. Easily maintained and designed for simplicity, they are customised to each installation and easily commissioned.

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Page 73

UDDERLEY FARMING GEA Bail Restraints, automatic cup removers and clusters have transformed the milking experience at the Wellman farm.

GEA’s David Jones and Aaron Potter of AG Water in the upgraded shed.

Debbie Wellman ‘loves’ the ease of handling of the GEA iC330 clusters.

David says the iCRS cow restraints are controlled by the cluster removers – “dropping down behind the cow only when the cow kicks off the clusters or is still milking when approaching cups off ”.

To spread the cost of the upgrade, Aaron recommended installing the cluster removers and new clusters before the start of the 2019 season, followed by the cow restraints in January 2020.

In contrast with their first year of milking, the second season was “a breeze,” says Debbie.

“The new clusters are fantastic, light and easy to handle and there’s no slippage. A button, positioned at knee-height on the outside of the platform, is easily pushed as we apply the cups to start pulsation.

“We now need only one person in the shed with another bringing the second mob in and milking

A simple bracket modification was required to retrofit the GEA iCR units.

takes no more than 2.5 hours in the peak.

“The retrofit has really changed the entire milking experience. It’s a simple system, which works every time. There’s minimal fuss and less labour with no ongoing repairs and maintenance.”

E˜ uent revamp In conjunction with the dairy upgrade, the farm’s effluent system also received a total revamp.

Shanan says when they purchased the farm it had “water irrigation over around 100 hectares but the effluent system was simply a small sump near the shed”.

The new system comprises of a large solids pond, which only needs emptying twice-a-year.

From there, liquids go through a weeping wall

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140°

The super-sized 4 million litre effluent storage pond futureproofs the farm for up to 600 cows.

The capacity of the solids storage pond means it only has to be emptied twice-a-year.

and then into two tanks for flood-washing the yard. The balance of the liquids are stored in the 4 million litre effluent pond, which features a Viking Containment pond liner.

The effluent and storage ponds were constructed by P.R. Leslie Contracting of Linkwater.

The welding and testing technology for Viking Containment’s Agrishield liners incorporate a non-destructive test system. The dual track wedge welds allow all seams to be pressure-tested, giving heightened confidence of effluent containment.

Future enhancements With the dairy fully functional, Shanan and Debbie Wellman can now focus on improving cow production, pasture and other elements of the farm.

180°

“At this stage we don’t envisage increasing cow numbers but know that, if we should, the dairy and effluent system would handle it,” says Shanan.

“The current holding yard is a bit restricted, only holding 360 cows, so at some point we will extend that. Currently, effluent is irrigated across 40ha of the farm and in the future we will extend this to cover 120ha.”

Looking back, Debbie says the move from the Waikato to the Rai Valley “has been a great move”. “We thought we’d be homesick for the Waikato but we haven’t missed it at all; it’s so relaxed and stress-free down here.

“The farm is just down the road from French Pass so we’ve got great fishing and hunting on our doorstep and Nelson’s only 30 minutes away.”

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Page 74

NEW CREEK JERSEYS

Production boost

Coast & Country

Clare Bayly

The Sorensen dairy at Okaramio, Havelock.

Frederik Sorensen with his mother Lone Sorensen.

The difference in milking environment on a Havelock farm has delivered a measurable return on investment – increased milk production of 40kgms per cow.

The 500-cow Jersey herd had been producing around 410kgms in the “old 30-aside herringbone” but this production increased by 10 per cent to 450kgms per cow in their first season in the new rotary.

That increase, according to Frederik Sorensen, validates the investment in a 54-bail rotary during a time of fluctuating milk price.

“My parents, Tony and Lone, moved here in 1995 from the West Coast where they’d been dairying. Back then, they milked around 145 Jersey cows on a milking platform of around 50 hectares.

“Over the last 15 years we gradually acquired neighbouring properties as they came on the market and today the total farm is 450ha with a 170ha milking platform milking 500 cows in the 2019/2020 season.

“In the spring of 2020 a new bridge will bring in a further 20ha, increasing the milking platform to 190ha.

Frederik started talking seriously about replacing the old herringbone in 2018. “At that time it was taking around four hours to milk the 480-cow herd twice-a-day.”

Clear objectives “My parents and I had a very clear set of objectives for the new dairy. We wanted to reduce the distance the cows had to walk to and from the dairy and wanted to reduce milking time.

“We also wanted to build a bridge, which would enable us to bring another 20ha into the

Feed silo and water supply tanks are positioned to the rear of the dairy. milking platform and increase cow numbers.

And last, but not least, we wanted to create an environment which would attract and retain quality staff.

“We opted for a 54-bail rotary because it meant one person could efficiently milk upwards of 560 cows.”

Lone Sorensen recalls the decision to build the new rotary was made in the spring of 2018, with the contract for the milking plant going to Read Industrial.

Tragically, within weeks of signing the contract to build the new dairy, Tony Sorensen died suddenly.

“Tony and I originally hail from Denmark, where Tony was very involved in Danish Jersey breeding. Our love for Danish Jerseys continues to this day with strong, big-framed cows that produce and hold their place in the herd well past 16 years,” says Lone.

Construction of the new dairy commenced in

The Read ECRs have a range of preset parameters, which are accessible via an intuitive touchscreen on each ECR.

November 2018, six weeks after Tony died.

The site for the new build is in the centre of the farm to minimise walking distance for the herd. Earthmoving company P.R. Leslie Contracting did all the site works for the new dairy as well as the new effluent pond.

“We chose Read Industrial for the milking plant because we’d worked with them before and liked the robustness and simplicity of their gear,” says Frederik. “We wanted something which wasn’t overly fussy and that would work from day one.

“We plan to milk 560 cows in the 2020/2021 season and, not wanting to limit ourselves, had the dairy spec’d for 700 cows.”

Semi-automated Phil Read says his company, Read Industrial, has been involved in the design and manufacture of dairy milking systems for New Zealand farmers “for close on 100 years”.

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NEW CREEK JERSEYS

PH 07 578 0030

The new Sorensen dairy is equipped with electronic cup removers, automated bail arm control and automated teat spraying.

The dairy is spacious and light-filled providing “a wonderful working environment”.

Frederik and Lone Sorensen with Phil Read of Read Industrial.

“Our focus is on producing semi-automated dairy milking technology coupled with reliable mechanical pulsation. Our systems are efficient, low maintenance, practical and simple to operate.”

And that was what Frederik and Lone wanted. A functional dairy that would be easy to operate and maintain, creating an optimum environment for cows and humans alike.

Phil says the new Sorensen dairy is equipped with electronic cup removers (ECRs), automated bail arm control and automated teat spraying.

“Our cup removers have programmable parameters, which enable them to be customised to each herd. All Read rotary systems come with sliding mechanical pulsators, which are guaranteed for 10 years but we have installations that have functioned correctly for 30-plus years without any maintenance at all.

“The simplicity of our systems is evident in the ECRs, which are activated when the cups

are lifted and applied to the cow. In effect, the ‘auto start’ triggers cluster release as well as cup end vacuum and bail arm lowering. The ECRs have a range of preset parameters; for example, letdown delay, milk flow, kick-off alert, maximum milking time etc, which are accessible via an intuitive touchscreen.”

Electric family Thompson Electrical Ltd, a family owned and operated business was called in to do all the wiring for the new dairy.

“We are pleased to have been involved with the electrical project for the Sorensen’s dairy at Long Valley,” says Kevin Thompson.

“The electrical work involved a lot of forward planning for it to all come together and it was great to work with a well organised team of builders and engineers, which made our job a lot easier.”

The drilling and construction of the new

The dairy’s milk room is positioned in one corner of the dairy.

dairy’s water bore was carried out by Blenheimbased Butt Drilling. Since it was established in 1990, Butt Drilling has completed more than 1900 water wells in the Marlborough area and have extensive understanding of the region’s aquifers and ground conditions. Think Water designed and installed the water system for the new dairy comprising of a new bore pump shed supply, dairy shed water reticulation, pumps, pipework, and washdown systems. A new effluent pump and system drawing from the new pond was also fabricated, installed and connected to the effluent mainline.

The new dairy includes an LIC Protrack ID Rotary system, which combines automated drafting with in-bail animal identification. The system is fully integrated with MINDA LIVE providing Frederik with real-time insight to treatment or withholding cows, slow milkers and feed groups.

Cows are identified by an EID reader as they step onto the platform with each cow’s

status displayed on the pit PC with an audio alert, when required. For example, mastitis or treatment cow.

Simplicity of use Frederik says one person was easily able to milk 500 cows in the 2019/2020 season with another person bringing the second mob in “where previously, in the herringbone, we needed two people in the shed”.

“We’re very pleased with the new dairy. Its simplicity of use means we are not as reliant as we have been on staff – in a pinch we could manage by ourselves but we are confident the new dairy will attract and retain great staff. It’s a wonderful working environment!”

Frederik and Lone Sorensen say after-sales service is vital. While they don’t yet have a generator there is capacity to add one and they are pleased that Read Industrial is “just a phone call away”.

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The LIC Protrack ID Rotary system, which combines automated drafting with in-bail animal identification.

Page 76

Platform

BECKSIDE

Coast & Country

for the future Clare Bayly

The composite deck has a higher level of resistance to chemicals than concrete alternatives.

The Morris-Eyton family – Robert and Rowena with their son Patrick and family – have farmed their Beckside property at Cumbria in the UK for more than 300 years. Today the farm operates a diverse range of enterprises including construction, hydro power, sheep and dairy.

Patrick Morris-Eyton says ensuring the future viability of the 263 hectare dairy operation led to an extensive redevelopment in 2019.

“The 250-cow Beckside herd is made up of home-bred pedigree Holsteins, which produce around 2.3 million litres of milk per year. Until 2019, we were milking twice-a-day in a 12/24 herringbone parlour built in 1994.

“The old parlour had been upgraded over the years but was starting to show its age. It was taking around three hours at each morning and afternoon milking to milk 210 cows, which was excessive for the operators let alone the cows.”

Patrick says the redevelopment of the dairy farm centred

around an increase in head count. Achieving that called for a parlour that would facilitate rather than limit current and future expansion plans.

“One of our immediate requirements was to develop a facility that would enable one person to easily milk 200 cows per hour – for example, more than twice what we were previously doing.

“After much discussion, the family decided to build a new state-of-the-art milking parlour and cow housing.”

Patrick says they spoke with people who operated rotary parlours and also visited working rotaries to gain a perspective on available options.

“The weight of concrete or steel platforms was a concern because of the impact weight has on the running gear. This led us to research the composite platform developed by Waikato Milking Systems.

Lighter, stronger platform “The Centrus rotary platform is significantly lighter and stronger than traditional decks, two factors which have been proven to reduce wear and tear,” says Patrick.

The new parlour has delivered the efficiencies the farm was looking for.

“The Centrus deck also has a higher level of resistance to chemicals than concrete platforms. This gave us confidence that the deck surface would be more durable than surfaces which pit from exposure to chemicals and the milking environment.”

Patrick also had a perspective, borne from personal experience, of the quality and ease of operation of Waikato Milking Systems’ rotaries.

“I’d milked in a Waikato Milking Systems rotary while in New Zealand and really liked the simple layout and ease of use.”

The need to create an environment where one person could easily milk upwards of 250 cows saw the family select a 54-bail Centrus rotary platform with a range of automation options.

“We had automatic cup removers in the old parlour and opted for the latest option, SmartECRS which are electronic and highly efficient ensuring cows are never over-milked.

“We also had an automated spray system in the old herringbone but Waikato Milking Systems’ SmartSPRAY system is a significant upgrade, ensuring that each udder is sprayed at every milking.

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The receiver group including the Bail Marshals and Milk Pump Variable Speed Drive.

Bail Gate straps hold each cow on the platform until she has finished milking.

The quietness and comfort of the new parlour saw the herd settle to their new environment by the third milking.

“Consistent application gives us a degree of comfort that we are positively impacting on udder health and Somatic Cell Count.

“As part of our contract requirements we are required to have milk meters to record milk data and, with a pedigree herd, like to have depth of data to support breeding and management decisions.”

Each cow an individual The new parlour was also fitted with the Waikato Milking Systems’ NaviGate Dairy Management System.

“NaviGate gathers milking automation data on each cow and presents it in a user-friendly way via the parlour console, enabling us to make informed decisions. The system allows us to treat each cow as an individual within the herd. It also automatically sorts and weighs each cow at the end of milking time.”

The new Centrus rotary platform was installed and commissioned in October 2019.

Patrick and family anticipated the cows would need time to get used to the new environment – transitioning from a herringbone to a moving platform.

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“We started with 70 cows and they were hesitant stepping onto the pristine – and different – environment of the new parlour.

“However, once on the platform the quietness of the milking system combined with the comfort of the bails with rubber flooring saw them arrive at the second milking much more relaxed. By the third milking, they walked on no problem at all.”

Patrick says with the first 70 settled, they then added another 50 cows. “They adapted easily, following the lead of their herd-mates.

“Following that, when the herd housing was completed, we added another 120 cows through the rotary and that was a bit tricky because there was a higher number of cows unused to the new environment.

“But again, within three milking times, they all came onto the platform no problem at all.”

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Page 77

BECKSIDE

PH 07 578 0030

“We are currently on twice-a-day milking but intend to go three times-a-day in 2020.

The redevelopment of Beckside Farm attracted interest from neighbouring farmers – in particular the Centrus rotary platform, which is considered revolutionary in design and performance.

“They like the milking automation technology that enables the milking parlour to do more than it would traditionally be capable of, with less operational hours.

“They also saw that working with the Centrus was easier on the cows and the operator.”

Patrick has some key advice for other farmers looking to redevelop their old dairy parlours.

“Work out what you want from a parlour and don’t cut corners on technology that can make your life easier. A new parlour will be there for many years to come. You will spend plenty of time in there, so you want it to be comfortable for both you and the herd.

“With that in mind, keep things simple – don’t over complicate your planning but don’t be afraid of technology.”

WALSH

Page 78

Drawcard

Coast & Country

Clare Bayly

The new 50-bail rotary milking parlour on the Walsh family farm in Ireland is proving to be a drawcard for staff.

“Ireland has almost full employment so labour is becoming a real challenge,” says farmer Henry Walsh.

“The farm’s location, close to a city in County Galway, compounds the problem as people have lots of employment options. The consequence for us is that it was always difficult to attract and retain skilled labour.

“That’s all changed now – people want to work with modern systems and technology and the new parlour is attracting a lot of labour.”

Henry and Trish Walsh, together with their sons Enda and Aidan, originally milked 50 cows through a 16-aside herringbone.

“We needed to futureproof the farm for Enda and Aidan and so we progressively increased the size of the herd to 300 cows. That put a huge amount of pressure on the old parlour so we began looking at the options for a new, larger herringbone.

“Enda and Aidan had both worked in rotary parlours and when their enthusiasm was reinforced by our discussion group, we decided to switch to a rotary as this would allow us to continue growing and would futureproof the farm for our family.”

Milking Systems’ rotary parlours – both sons having milked in them in New Zealand and Australia.

“We met with Waikato Milking Systems’ European sales manager Gillian FullertonSmith, who is based in Ireland. She was our first point of contact and highlighted the advantages of the Waikato Milking Systems rotary parlours and the technologies we could incorporate to achieve our goals.

“We wanted a basic milking parlour that would make the cows comfortable, reduce Somatic Cell Count and enable good production with low maintenance costs,” says Henry.

Those requirements were realised in a 50-bail Orbit Concrete Rotary parlour with SmartECR electronic cup removers, BailGate Straps, SmartSPRAY and SmartWASH. “BailGate Straps were a must. We estimated it would take around 11 minutes to milk each cow, but there would still be some who would take longer so we had to have the ability to hold them on the platform.

“Teat health and SCC are very important and SmartSPRAY, which automatically sprays each cow at every milking, gives us the reassurance we wanted.”

Primary goal Henry says their primary goal was to make it a one-person operation. “Initially, we thought a 40-bail rotary would be big enough but we eventually decided on a 50-bail as, in addition to ease of milking, this would futureproof us for growth in herd numbers.”

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One-person parlour Henry Walsh is urging farmers to look critically at the time spent in the parlour and ask themselves if their current parlour is futureproofing their farm.

A number of technologies were included in the new dairy to ensure the family was able to achieve its goal of a one-person parlour.

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The exterior of the new parlour at the Walsh family farm in County Galway, Ireland.

“The SmartECR automatic cup removers mean one person can easily and efficiently milk 300 cows. Automatic washing of the clusters, with SmartWASH, means we simply put the clusters into the wash position, push a button and walk away.”

The new milking parlour was constructed on a greenfields site adjacent to the old parlour.

Installation took place during the Northern Hemisphere summer and autumn of 20192020. During construction, the family was able to continue milking in the old parlour, transitioning to the rotary in August 2019.

“We anticipated some training would be needed for the cows moving from a herringbone to a rotary,” says Henry.

“We set up a little race, which allowed us to funnel the cows through the exit race across to the entry point of the milking parlour. This meant the herd couldn’t, from a distance, see that they were going on to a new parlour.

“From there, we had to push each cow onto the platform during the first milking. We used

Page 79

WALSH

PH 07 578 0030

three people and stopped the platform from rotating each time, so the cows weren’t walking on to a moving platform.”

Henry recalls that in-shed feeding incentivised the cows to become accustomed to their new environment.

Enticement “The cows were fed 3kg of meal each and this proved to be a motivating factor to encourage the cows on to the platform. At the second milking, some cows were even brave enough to step onto the platform to get to the meal, meaning we only had to push around half of the herd.

“By the third milking, there were only a small number of cows who needed to be encouraged to step onto the platform. After that we had to be careful around the entry because the cows were so keen to get on for the meal.”

From an operational perspective, Henry says the new parlour is simple to operate.

Construction of the 50-bail Orbit concrete rotary took place during the summer of 2019-2020.

“The new milking parlour’s main advantage is its ability to reduce labour time at milking.

“We’ve cut down our milking time by half, probably taken off about 13 hours from our working week.

“On top of that, we’ve massively reduced the effort we have to put in at milking time.

It’s nowhere as strenuous as it was milking in the herringbone parlour and is a much more relaxed environment for us and the cows.”

In January 2020, Henry and Trish travelled to New Zealand to visit Waikato Milking Systems’ headquarters in Hamilton and visited Waikato farmer Peter Risi, who is milking on a similar Orbit rotary parlour.

Smart move After speaking with Peter, Henry and Trish are considering adding SmartD-TECT to their parlour to resolve some issues they had with mastitis during the previous season.

“The SmartD-TECT system will pick up

problems very early on and show signs of mastitis giving us an opportunity to improve cow health and productivity.”

Reflecting on their journey from a relatively small herringbone parlour to a 50-bail rotary, Henry has some advice for other farmers in Ireland looking to increase their herd sizes and upgrade milking parlours.

“More herds in Ireland are moving past the 300-cow mark and this is placing pressure on old, outdated parlours and increasing milking time.

“Milking in, say, a 24-point parlour for 2.5 hours, is getting to the cut-off point in terms of the time people can tolerate before they get physically and mentally tired.

“When you reach that point you really need to stop and consider an investment which will futureproof your farm into the future.

“For us, the simplicity of the Waikato Milking Systems’ parlours really stands out. No bells and whistles but a system that functions well, is reliable and takes care of us and the animals.”

REAL GRASS

Page 80

German dairying Clare Bayly

German farmers at the open day were keen to learn more about pastoral dairy farming.

The RealGrass Group’s Netzen farm is the only full-time pasture-based dairy operation in Germany.

Kiwi expertise in the design and production of milking systems and genetics, which maximise the benefits of pastoral dairy farming, is changing the face of dairying in Germany.

Traditionally, dairy cows are housed indoors in Germany – and at best get to venture outside for six hours per day 120 days a year – but in 2014 the RealGrass Group challenged the norm, developing a pastoral dairy farm in Netzen, southwest of Berlin.

Based on the validated science and innovation from New Zealand and Ireland, the farm aimed to graze cows outdoors for 365-days-a-year with housing available to the herd during the most extreme weather.

The farm is the only full-time pasture-based dairy operation in Germany – but the output it has achieved since it was established in 2014 is challenging conventional thinking and has the potential to change the face of German dairying.

Vicky Lynch from The RealGrass Group says the motivation behind the farm’s development is to provide “milk produced from grassfed cows to the consumer”. “Our cows are outside every day of the year, producing milk off pasture.”

Transition Transitioning from an enclosed to a grassbased system required a rethink in terms of genetics and dairy systems, says Vicky.

“We fenced off 400ha of pasture, installed water and roadways, reseeded grass and switched to seasonal calving.

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“Using genetics from New Zealand we gradually changed the genetic base of the herd from Holstein to Jersey Cross as crossbreds are reputed to be more robust and healthy, with fewer health-related issues than Holsteins.”

Until 2018 the 950-cow herd was milked in a conventional indoor milking parlour, which had been built to suit large-framed Holsteins.

The new parlour needed to provide an optimum environment for the farm’s herd and staff with a high level of technology, which would promote efficiency and measure production. And all of this had to come in a parlour that was easy to operate.

“The RealGrass Group looked at a variety of rotary dairy parlours around the world before we eventually decided on a 60-bail Centrus

Guests attending the open day with Waikato Milking Systems’ European sales manager Gillian Fullerton-Smith on right. rotary platform from Waikato Milking Systems,” says Vicky.

The Centrus Composite Rotary combines extreme lightness and strength in a platform proven in some of the most intensive 24/7 dairy operations around the world.

“The fact that the Centrus could be tailored and optimised to fit into the farm’s existing building was a huge advantage,” says Vicky.

Specifically tailored “Waikato Milking Systems was the only manufacturer in the world that could design and manufacture a rotary platform tailored specifically to our operation. We were able to get the precise size platform we wanted and were also able to size each bail to provide maximum comfort for our cows.”

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REAL GRASS

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The fact that the Centrus could be tailored and optimised to fit into the farm’s existing building was a huge advantage to Germany’s RealGrass Group.

Visitors to the farm’s open day were interested in the farm system and the new parlour.

Vicky says the single-bail modular design provides a unique assurance of return on investment “because, should we ever have to replace a section of the platform, it is possible to simply replace that segment – not the entire deck”.

“The ability to tailor the new parlour also extended to the bails, which are sized to our crossbred cows but can be adapted to larger-framed Holsteins should the company ever change its breeding strategy. This degree of flexibility future proofs the parlour into the future.”

Cow comfort in the new parlour is enhanced with specially formulated and replaceable rubber mats in every bail. The mats are soft to stand on and promote a quiet milking environment.

The Centrus Rotary platform’s lightness – 75 per cent lighter and more durable than traditional concrete or steel alternatives – reduces overall wear and tear translating to less maintenance.

Technologies “Achieving our goal of a parlour that would reduce labour and make milking, breeding, handling and sorting of animals easier led to the inclusion of a range of technologies, all of which can be updated as and when new advances are made,” says Vicky.

Smart change technology enables easy changing of the single-flanged Multi Rollers without the need to cut into or remove sections of the I-Beam.

Technologies include SmartECRs automatic cup removers, BailGate Straps to hold cows on the platform, a SmartSPRAY automatic spraying of each cow at every milking, the SmartWASH automated cluster and machine washing and Yield Indicators.

The NaviGate Dairy Management System measures, monitors, maintains and provides oversight of milking, managing cow performance and issuing alerts to critical health issues.

Three-way automated drafting is provided by a NaviGate Sort Gate, which allows drafts to be preset ahead of, or during, milking.

The parlour’s veterinary platform is used for a range of functions from dosing cows to artificial insemination.

The Centrus Rotary Platform arrived in a series of containers, accompanied by a specialist team from Waikato Milking Systems, who oversaw the unloading, construction and commissioning of the parlour.

The parlour was commissioned in 2019 and is now being used to milk the farm’s 950 cows.

The RealGrass Group opened the farm to the public shortly

Innovative Design Improves Efficiency Ezi-flo pit gates completely clear exit ways and cannot be touched by cows leaving the milking area.

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Bails are heavy duty and feature BailGate Straps, leg spreaders and rubber matting.

after the new parlour was commissioned.

Vicky says a large crowd attended, noting that many “were as interested in the unique characteristics of the Centrus Rotary Platform as they were in the philosophies and practices which drive the overall farm”.

Robust and user-friendly “General feedback was that few, if any, farmers had ever seen a rotary platform as robust and user-friendly as the Centrus.

“The day certainly prompted and challenged conventional German thinking about traditional practices and systems,” says Vicky.

Several months on from commissioning, Vicky says the RealGrass Group is delighted with the new parlour.

“The milking environment is very quiet and calm and this has an obvious benefit for cows and people alike.

“Team morale has really improved. The technology is intuitive and easy to use and this has generated a consistency, on the part of our staff, which is enhancing production, efficiency and productivity. Our staff love the Centrus as much as the herd does,” says Vicky.

Innovative Design Improves Efficiency

Ezi-flo pit gates completely clear exit ways and cannot be touched by cows leaving the milking area.

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Spec’d

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The cattle barns are located close to the parlour, minimising the distance cows have to walk to and from milking.

for tough environment

Large milk silos, cooling towers and tiled exteriors of the building enhance the overall appearance of the new parlour.

Clare Bayly

Due to civil works being delayed due to monsoons, the installation of the Multi Roller undercarriage commenced immediately after the roof was in place.

One of the largest dairy farm groups in China recently installed its sixth New Zealand-designed and manufactured rotary milking parlour.

Established in 1995, Junlebao Dairy Co, operates a growing number of sophisticated, large-scale 24-hour dairy farms across China.

With more than 8000 employees, the company has farms in Hebei, Henan, Jiangsu, Jilin and other provinces. Milk produced on the farms is processed into milk powder, low temperature yoghurt and liquid milk.

Waikato Milking Systems’ China manager David Morris says the group invested in its first Waikato Milking Systems’ rotary platform some years ago.

“The Junlebao Dairy Group applies very high

standards to the care and handling of its dairy cows, investing in technology which enable the farms to operate to maximum efficiency.

“Systems built to excel in a 24/7 intensive environment are a prerequisite. The group visited our headquarters in Horotiu, Hamilton, to get a hands-on appreciation of the engineering excellence evident in all of our systems.

David says their farms typically operate at least 21 hours per day, with three or four milkings taking place each day. “That continuous environment demands equipment, components and technology which are intuitive and built to the highest standards to ensure consistent, smooth operation day in, day out.”

The latest 60-bail Orbit Concrete Rotary milking parlour was commissioned on the Junlebao Dairy Group farm in the Hebei

Province of China in October 2019.

David says the newly developed farm is currently milking 1600 cows but aims to progressively increase the headcount to at least 2000.

“The new parlour is currently operating 15-hours-a-day, milking 1600 cows threetimes-a-day.”

Seldom stationary “In reality, the platforms are seldom stationary.

If they are not loaded with cows they are being cleaned and maintained to the highest standards to ensure a pristine environment for workers and cows,” says David.

“Our rotary platforms are spec’d for exactly that environment; that demand. We design and build milking systems to perform in the most extreme environments, their quality of

design and build minimising maintenance and downtime.”

David says due to the high milk flow rates at the Junlebao farm, twin 120 milk-line receiver cans were installed, coupled to a 100mm milk line. “As it tends to be on all Chinese high performance dairy farms, cleanliness standards are exceptionally high with reassurance in the new parlour provided by Waikato Milking System’s proven air injector wash system.”

David says the five other Orbit rotary parlours installed for the Junlebao Dairy Group “were all 80-bail milking systems”.

“Some farms had dual 80-bail rotary platforms, while others had one platform.

The number of cows and regularity of milking varies from farm-to-farm but all farms milk upwards of 3000 cows three or four times a day.”

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JUNLEBAO DAIRY GROUP China is well-known for its impressive architecture – and farm entrances are no exception.

All cows’ teats are pre-dipped and then wiped before cups are attached.

This requires two people with another person attaching the clusters. The panels behind the cows are designed to deflect effluent.

Exterior cladding and finishing work was conducted once the mud and slush from the monsoon was cleared from the site.

The Junlebao Dairy Group specified a 60-bail Orbit Concrete Rotary with Multi Roller undercarriage and AfiMilk herd management for the Hebei farm. “The Orbit’s ability to perform in extreme conditions has been proven over more than 25 years.

“The design of the platform provides milkers with a clean, fast-milking environment with excellent cow flow. The extra wide 2.7m deck has a wide walk-way in front of the cows and provides excellent protection for milking and electronic equipment.”

David says that, traditionally, concrete rotary platforms have had a reputation for exacting wear and tear on the support systems on which they sit and turn.

“Waikato Milking Systems is one of the leading innovators in rotary dairy platforms and technology. Over the years we have

developed support undercarriage systems which resolve the weight issue.”

Multi Roller undercarriage The new parlour at Junlebao’s Hebei farm features a Multi Roller undercarriage made from nylon polymer material, engineered for industrial applications.

“The Multi Roller is Waikato Milking Systems’ latest offering in platform track options,” says David.

“The Multi Roller utilises two I-beams and a set of industrial grade nylon polymer rollers contained within a unique fixed carriage to form the bearing surface the platform sits on.

“The weight of the platform is evenly spread across a greater number of rollers increasing its durability.”

To enhance cow flow, short sections of fence are added to the yard to line the cows up before they approach the specially-angled single-access entrance race to the rotary.

“A significant and unique feature of the Multi Roller system is that it is relatively easy to replace the single flanged rollers without the need to cut into or remove sections of the I-Beam.”

David says the Junlebao Dairy Group was one of the first in China to use American HolsteinFriesian cows, which can weigh up to 900kg and produce 45 litres of milk per cow per day.

“Heavy duty bails, which are an option on our rotary platforms, provide the perfect environment for these large-framed cows. The quiet milking environment coupled with wide bails and rubber matting underfoot ensures cow comfort, which has a positive impact on cow flow and production.

“Three people work in the dairy, all positioned at cups-on. There’s a high focus on cleanliness with each person charged with

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pre-dipping, wiping, stripping and applying the clusters. The deck of the platform has leg spreaders, which make it easier and faster to apply the cups,” says David.

Specialist team “The rotary arrived on-site in Hebei ready for our Waikato Milking Systems-trained Chinese team of specialists to assemble the rotary platform. The parlour was commissioned by our New Zealand specialist team.”

David says due to a number of typhoons that passed across China during the construction period, the project was delayed by several weeks. “To offset this, our installation team worked extended hours to ensure the parlour was completed on time.”

CLINTON

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Coast & Country

Wisconsin

wonder Clare Bayly

The Centrus Rotary Platform was a drawcard for more than 800 people at an open day to showcase the farm’s redevelopment.

The impressive entrance to Clinton Farms’ new parlour.

The new parlour on the Clinton Family farm in Bear Creek, Wisconsin, has shaved 12 hours a day off the three-times-daily milking of their 500-cow herd.

Brad Clinton says the original double-up milking parlour at Clinton Farms’ property in Bear Creek was built for an earlier time.

“It was pretty efficient when we had a smaller herd. You could milk about 90 to 100 cows per hour.

“Over the years, however, we’ve progressively increased the size of the herd to 500 cows and this put the old parlour under pressure with each milking taking up to six hours.

“It simply wasn’t sustainable from any perspective,” says Brad.

The Clinton Family Farm produces about 80 pounds – or about 37kg – of milk per day per cow and supplies Saputo Dairy. The property is 930 hectares and the farm grows its own feed for the herd and some cash crops.

“In 2018, we launched a major expansion programme and at the top of the list was a new labour efficient milking system that would provide the flexibility, in terms of cow numbers, this farm needs to remain viable into the future.

“I’d always liked the concept of a rotary parlour but had some concerns about the weight of traditional concrete and steel platforms, which are in use, as we are [milking] three-times-aday.

50-bail, which would futureproof us with the scope to milk up to 2000 cows three times a day.”

The decision to build a Centrus rotary platform was accompanied by an extensive range of technology to maximise labour efficiency and cow health.

SmartECR electronic cup removers ensure cows are never overmilked while SmartD-TECT monitors and measures pulsation and milk conductivity. Yield indicators measure milk volume.

Radical design

Cow comfort

“Some years earlier we had heard of a company that had developed a radical new rotary platform constructed from a composite material. The result was a deck which was 75 per cent stronger than concrete or steel, but which was lighter.

“The decision to build a new parlour enabled us to take a closer look at the Centrus rotary platform designed and manufactured by Waikato Milking Systems. We were very impressed with the quality of the deck and decided to build a

Cow comfort is a central theme of the Centrus rotary platform with rubber matting in every bail. This is complemented in the Clinton parlour with heavy duty bails that accommodate largeframed cows.

The parlour’s SmartSPRAY system automatically sprays each cow’s udder before and after milking, providing a consistent defence against mastitis and a positive impact on Somatic Cell Counts.

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Milking time has been reduced from 18 hours per day for three milkings, to six hours.

The Bail Marshal manages connectivity and communication between all the bail devices.

Cows moving from the collection yards to the new platform.

The constant flow of the rotary platform enables Clinton Farms to milk 500 cows three times a day.

The NaviGate Sort Gate is also part of the dairy management system, allowing Brad to automatically sort cows using animal ID reader technology as they come off the platform and exit the parlour.

Real advantage All of the data generated by the automation options is gathered by the parlour’s NaviGate Dairy Management System. The information can be viewed on a console in the parlour and farm office, enabling better informed decisions about how to manage the herd and maximise cow health and production.

In 2019 the Centrus Rotary Platform arrived in a series of containers, accompanied by a specialist team from Waikato Milking Systems, who oversaw the unloading, construction and commissioning of the parlour.

Clinton Farms held an open day to showcase

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CLINTON

their redevelopment in September 2019 and “the new parlour was a drawcard,” says Brad Clinton.

“Around 800 people from Wisconsin and the surrounding area came along and there was a lot of interest in the Centrus rotary platform.

The concept of the composite deck was quite well-known but this was, for many, the first chance they’d had to see one in operation.”

Since it was commissioned the parlour has been milking 500 cows three-times-a-day and Brad says the “constant cow flow the rotary platform delivers is a real advantage”.

“You’re not milking 20 cows at a time with the other 20 just standing there as you are in a double-up. The constant flow of cows coming in and out is very appealing and efficient.

“Moving from a double-up to a rotary was a big step but the new milking system is logical and easy to use.”

Brad says it took two or three milkings for the

Tanks for the parlour’s SmartSPRAY system, which automatically sprays each cow’s udder before and after milking. herd to become used to stepping onto and standing on a moving platform but they settled fairly quickly. “You notice it’s always the same cows that walk on first and the same cows that are the last to get on; they’ve got their own order.”

Peace of mind Brad says the NaviGate Dairy Management System provides them with a level of insight to each cow that they’ve never had before. “Data is displayed on the console in the dairy and farm office so we can see what’s happening as it happens, and refer back to previous milkings if we want to make comparisons.

“Basically, it lets you know what’s going on with your herd. Gone are the days when you had to totally rely on your milkers to notice everything as the cows were being milked.

“It gives you peace of mind that things are getting done the right way and you know you’re

getting a consistent milking routine.”

Milking time has changed dramatically with the new parlour. “In the old double-up parlour, in three daily milkings, we could spend 18 hours a day milking 500 cows. Now it takes two hours per milking, or six hours per day.

“Basically, the time we’d spend before in one milking, now equals the time we spend in the parlour each day. That time-saving is significant not only for milkers but for the cows as, instead of standing around waiting to be milked, they are grazing and making milk.”

“The Centrus Composite rotary platform will give Clinton Farms the ability to expand our dairy operation in future.

“At the moment we’re milking 500 cows three times a day but the new parlour could handle 2000 cows if we want to get that big; there is plenty of room for expansion,” says Brad.

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Coast & Country

TIMES ARE CHANGING FOR IN SHED FEED SYSTEMS FOR HERRINGBONE SHEDS The PPP Smart Hopper is a game changer for HB in shed systems A feed system that can also ID your cows in the shed.

With the development of the new patented travelling feed hopper for HB sheds farmers finally have a tool that will offer them the advantages of a rotary shed. A unit that can feed out more than one type of feed with an inbuilt mineral dispenser.

Quietly and with amazing precision it distributes individual recipes if linked to herd management software or easily adjusted recipes of different feed amounts and types between milking’s if just blanket feeding in its simplest form.

Feed more than one type of dairy ration at the same time (similar to rotary sheds) with the added advantage of an in built mineral dispenser.

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