New Farm Dairies 2014

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Showcasing the nation’s newest dairies Showcasing 35 of New Zealand’s newest dairy farm developments throughout New Zealand

NEW FARM DAIRIES

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Coast & Country

Biggest issue yet reflects dairy’s growth

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.

No.1 The Strand PO Box 240 Tauranga 3140 phone 07 578 0030 fax 07 571 1116 email lois@thesun.co.nz

Lois Natta Sarah Adamson Advertising Graphic Designer 027 281 7427 Page Layout Coordinator

Brian Rogers Director/Editor

Claire Rogers Managing Director

Merle Foster Journalist

Elaine Fisher Editor

FRONT MAIN PHOTO COURTESY SUPPLIED BY WAIKATO MILKING SYSTEMS

Just like the dairy industry, New Farm Dairies is growing. This is our ninth annual edition and at 120 pages, our biggest ever.

New Farm Dairies is the only specialist publication focusing on new dairy buildings from the top of the North Island to the tip of the South Island and since its first issue in 2005, has gained a reputation as a reliable resource for anyone considering building or upgrading a farm dairy.

Thirty-five new dairies are featured in the 2014 issue, but many dairies have missed out because bookings for inclusion weren’t made early enough, says New Farm Dairies consultant Lois Natta.

“I already have eight bookings for the 2015 edition and if anyone wants to be part of it, they really need to book before the end of October 2014,” says Lois.

“This year’s edition features just

one goat dairy, but we’d like more in the 2015 edition to reflect this growing aspect of our dairy industry.”

It’s not just new dairies which can feature in the publication. Significant new cow barns and feed pads, and the associated infrastructure, are also worth profiling.

It is Lois who co-ordinates journalists, dairy owners and representatives of all the trades and service companies involved in each project to meet on-site, for interviews and photos. She also visits and writes about some of the new projects too.

“What has really impressed me this year are the effluent storage and handling systems which farmers are installing. The engineering and technology going into addressing effluent issues is outstanding and reflects how seriously the best farmers take environmental issues.”

There’s an increased recognition of the value of attracting and retaining top staff too.

“Many farms are building really lovely modern homes for their staff and it makes sense. It’s worth making an investment in housing for top staff to ensure they stay on the farm.”

“Cold, inconvenient old farm houses aren’t going to retain workers.” Our team of journalists have once again been impressed at the standard of new dairies being built and the willingness of dairy owners and those companies involved in the projects, to share their knowledge and experiences.

The dairies featured here are among the best of the best and illustrate why building a new farm dairy requires a significant capital investment, and doing it right ensures a building which will benefit the farming venture for years to come.

To be featured in New Farm Dairies 2015 – call early to avoid disappointment.

Contact Lois Natta on 07 378 9091 or 027 281 7427.

Publishers Brian & Claire Rogers

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NEW FARM DAIRIES

Effluent top worry for many farmers

Cows are efficient converters of grass into milk, for which there is a ready market.

But the byproduct of the process is more problematic. Cow effluent is high in nutrients but on today’s dairy farms there is so much of it, it’s too much of a good thing.

Fifty years ago farmers gave little thought to cow pats in the paddock, other than that they increased the worm population; and effluent in dairy shed yards was washed into drains or creeks with no concern about where it ended up.

Today’s large herds mean such practices are totally unacceptable. However, farmers still face the dilemma of what to do with all that effluent.

Councils are getting tough on farmers; and failing to have a consented, modern effluent system can even see them ordered to stop milking.

It’s not surprising that how to deal with effluent is top of farmer woes, according to farmers who attended this year’s Fieldays and gave their thoughts to the Innovation Centre’s new drawcard, The Lab. The Lab, run by Tauranga-based Locus Research, asked farmers what their top five problems are on-farm – and effluent management was the main answer, says Locus Research product designer Simon Crane.

“The most common problem I’ve come across is effluent management on dairy farms. It’s expensive, timely, it takes a lot of time and the effluent when

they irrigate back onto pastures can go through the soil really quickly – and that’s when you get pollution into the waterways.

“How you manage that quickly and cost-effectively is a real big problem.”

Effluent regulation tightening is also a factor, says Simon. “The increasing amount of paperwork they have to do to comply with regulations was another thing I got from farmers – because the more time they spend on paperwork, the less time they’re spending on the farm.”

When new dairies are commissioned, they invariably include upgraded or completely new effluent systems and storage, aimed to reduce the impact on the environment – allowing farmers to use the effluent to spread on pasture and maize paddocks.

Page 3 FARM

DISTRICT

Kapuni 3 AFT Trust Corrigan Hockly Partnership Davidson Massey Rotopai Farm Panea Farm Red Dog Dairies Waipupumahana Trust Pengxin NZ Ltd Limestone Downs Welch Egg Co Thompson Dairies Rustic Dairies Ramul Farm Lagoon Valley Dairies Hitchen Creekside Pastures Auchenbrae Te Awa Land Co Riverholme Pastures McLelland Saywell JansonAg Netherland Holdings GSB Farm CIB Payne Lottisham Rowling Lynrich Trust Cranleigh Hills Upson Downs Farm Farmers Market

Taranaki Taranaki

Taranaki Taranaki Manawatu Manawatu Wairarapa Bay of Plenty Central Plateau Central Plateau Central Plateau Auckland Auckland King Country King Country King Country Southland Southland Otago Canterbury Canterbury Canterbury Canterbury Canterbury Canterbury Canterbury Canterbury Canterbury Waikato Waikato Waikato Waikato Waikato Waikato Northland

PAGE 4-9 10-11 12-13 14-15 16-17 18-21 22-25 26-27 28-29 30-33 34-37 38-43 44-49 50-53 54-55 56-59 62-65 66-67 68-69 70-73 74-77 78-81 82-83 84-85 86-89 90-93 94-95 96-97 98-101 102-103 104-107 108-109 110-111 112-113 114-115 116-118

KAPUNI 3

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Coast & Country

Fusing farms sees new Fonterra dairy Originally Fonterra owned two farms on the slopes of Mount Taranaki – Kapuni 2 with 36 hectares and Kapuni 3 with 119ha – which was close to the company’s Kapuni Manufacturing site processing lactose and high value lactose derivatives.

By Graeme Dobson

The majority of Fonterra’s dairy farms are located close to their manufacturing sites, where they’re used to irrigate waste-water from the manufacturing processes – an elegant solution to the waste-water problem

and a win-win for both farm and factory.

In this case both dairies needed considerable work to bring them up to Fonterra’s quality and compliance supply conditions.

So rather than spend the money twice, Fonterra’s dairy operations manager Paul Mahoney decided there were considerable efficiency gains in combining the farms into one 155ha unit, with one new 44-aside herringbone dairy and an upgraded effluent system capable of servicing a herd of 520.

As you’d expect Fonterra aimed for maximum value for money, hence Paul opted for a large herringbone that could be operated efficiently with just two milkers using a basic but top quality milking plant, a herd management system and snap chiller.

The job went out for tender with selection criteria that included an excellent Health and Safety record and policies, attention to detail and the ability to work with a large corporation – as well as the obvious prerequisites of quality design and workmanship.

Quintin Oakes from Stratford-based Quintin Oakes Builders Ltd won the building tender with a Chapman Dairy design 44-aside herringbone.

GEA Milfos was given the job of supplying the milking plant, and Agfirst Engineering Waikato got the job of designing the effluent system.

It’s not surprising Fonterra went with this combination; it represents quality all the way.

Chapman Dairy has franchised builders in many regions of NZ who are all busy keeping up with demand, because Chapman Dairy designs are very popular, mainly due to the huge wealth of experience behind them.

The dairy is a Chapman Dairy design, built by Quintin Oakes, of Quintin Oakes Builders Ltd.

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KAPUNI 3

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Maximum value for money at new dairy

That experience allows them to create blueprints to suit all situations. And their licensed builders, like Quintin, aren’t just very experienced in building – they’re also negotiators who talk to their clients about their needs and can adapt the basic design on-site to suit.

For example, this dairy is built so it can be easily and economically expanded to a 50-aside, if warranted at a later date. In the end, everyone comes out happy.

You know the owner is serious about health and safety when you have to sign in to the site when you arrive, and sign out when you leave.

But it’s not bad thing and is all part and parcel of Fonterra’s focus on work health and safety, which was a key focus throughout the dairy-build.

Fonterra project manager for job Anne Bridges says risk assessments were conducted

before starting, and Job Safety Analysis, spot checks and high visibility vests were mandatory.

“Contractors also worked with our health and safety advisor whenever a new phase in the project started that introduced a new risk,” says Anne.

So signing the book was the first thing Quintin had New Farm Dairies do; then he

was happy to show us around.

“This is a nice airy and light dairy, there’s windows all along the wall that can be opened in the summer to let the air flow through,” says Quintin.

“The roof slopes lengthways along the 38m length of the pit that mirrors the slope of the floor and keeps the distance from floor to ceiling constant.

For a more efficient farm dairy Specialising in farm dairy design and construction High cow flow efficiency Herringbone or rotary design Permanent & low maintenance All surfaces are easy to clean

Call us today for an on-site design consultation

027 230 0075 e quintin@qob.co.nz

Authorised licensee www.chapmandairy.com

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KAPUNI 3

Coast & Country

Quality all the way at Mount Taranaki least cow stress possible.“I’ve been a Chapman “It makes it uniform and very neat.”

Dairy agent for three years now, things have cerThe buildings, including the staff and milk tainly taken off in that rooms, are certainly clean; time,” says Quintin. and neat and the use of “I used to do one dairy preformed and painted a year; now I do three Coloursteel panels makes or four. Don Chapman it easy to keep that way. is a good bloke and easy Painting is kept to a to work with; and he’s minimum – there’s just a spent the time on the couple of timber rafters tools, so he knows the that run the length of the problems and issues.” building – and the paleThere’s always a coloured panels reflect a requirement for blocklot of light, which creates work in a herringbone a very bright, pleasant and here blocks were environment. used for the loading There are very few spaces ramp, tank stand and in for spider webs and bugs The bails are clean with heaps of room the pit. to get established and and windows for summer ventilation.

This is a specialist job nowhere for birds to settle; so Quintin brought in even the gaps between the tradesmen from local roof ridges and rafters have company Masonry Coninserts to prevent birds struction. from roosting, so there’s “They’re one of those no bird droppings – which hard-working gangs that should keep dairies regulajust do not stop. If you’re tor, Quality Consultants of pushed, you can be sure New Zealand, very happy. that they’ll get it done – “Provided they keep doesn’t matter what day the maintenance up, in it is, if the weather’s right another 10 years’ time this they’re there and workdairy will still look really Builder Quintin Oakes, of ing,” says Quintin. good,” says Quintin.

Quintin Oakes Builders Ltd. “And they put the same care and attention to Functional extras detail into laying blocks There are few frills with in dairies as they do in this building; everything is laying stones, bricks and blocks for my residential simple. But any extras, such as the step rails that work, so you always get a good job,” says Quintin. run down each side of the pit, are very functional.

Once in place the blocks needed sealing and Details like step rails are typical of a Chapman Dairy, as is the thought that goes into designing finishing to the high standard required by the yard layout to give the best cow flow and the Fonterra and QCONZ.

So they called in the best – Palmerston North-based painters Surfatex Ltd – to apply an Acraflex sealing coat to the pit walls.

Acraflex makes maintaining a high hygienic standard easy by sealing surfaces against bacterial build-up and presenting a very easily-cleaned surface.

Acraflex is ideal for dairies and gives a bright, attractive and extremely hardwearing finish.

“Surfatex Ltd is very accommodating and certainly spend a lot of time on the preparation work; they’re very fussy and they take pride in their work,” says Quintin.

“A lot of guys will spend two or three hours prepping, but Surfatex spent a day to make sure it was right. The job’s got a 10-year warranty and they like to make sure there won’t be any comebacks,” says Quintin.

GEA Milfos control units over the pit.

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Functionality thrills at Kapuni 3 That pride shows in the finish, which makes the blockwork an attractive feature – and it’s testimony to their quality and reliability that Surfatex do virtually all Chapman Dairy jobs from Hawkes Bay and Taranaki down to lower North Island.

Growing reputation

Another company with a long history with Chapman Dairy is Leask Engineering. In fact, they’ve been closely associated almost from the time Don Chapman first started building dairies.

Leask Engineering has been in business and specialising in dairies since 1958 when they pretty much pioneered herringbones.

Now they supply and install complete dairies from their Tatuanui factory in the Waikato, or they supply complete kitsets or just selected components.

At Kapuni 3, Leask Engineering supplied Quintin with the two gates to the bails.

But the engineering firm don’t just do dairies; they’ll do any other engineering jobs that come their way. Their reputation has gone far beyond the Waikato – they’ve been selling and installing steelwork in dairies as far away as Ireland and Pakistan, so they’re well up in the industry.

Inside the dairy, Fonterra had Glen Stevens from Dairypro 2010 Ltd install a GEA Milfos milking plant and chiller.

Pro installers Glen set up Dairypro 2010 Ltd in New Plymouth four years ago and became the GEA agents for the area; and one year ago he expanded into Stratford, to be better able to handle GEA’s work.

GEA Taranaki area sales manager Steve Nolly says the Milfos plant is a very good basic plant with swing arms for better cluster alignment, a Flomax milk pump, high capacity iC330 claws,

wash automation and pull-out jetters, tucked away at the side of the pit. “And it’s all designed to be upgraded, whenever they want,” says Steve.

Glen says there’s also variable speed milk pumps. “And everything here is interlinked in a network – pulsators, milk pump, vacuum pump, wash – so they can all be controlled from the pit or the milk room just by pressing milk, wash, purge or off,” says Glen.

“There’s also a Milksweep milk recovery that puts a pulse of air through the lines to push out the last of the milk.”

The iNTELWASH automatic wash is the most high-tech system Glen installed. The iNTELWASH washes the plant, fills the tub, recirculates the water through a series of valves, doses the chemicals and dumps the wastewater.

The iNTELWASH is very flexible and can be easily programmed to suit any requirements, so adjusting it to Fonterra’s standards wasn’t a problem.

Chilling suits changes Also designed to meet changing demands is the GEA iCONVERTER aquaCHILL ondemand chiller, which Fonterra had installed ready for anticipated changes in regulations that are likely to see a tightening of milk chilling requirements.

“The milk passes from the first plate cooler and into the aquaCHILL where it’s chilled with glycol before it’s put into the vat,” says Steve.

Once in the vat the milk is maintained at the correct temperature by Tru-Test’s Dairy Technology Services Milk Cooling and Tank Solutions refrigeration system.

DTS recently became a part of the Tru-Test Group, ensuring they’re able to offer their clients the best in farm technology.

At Kapuni 3 they’ve installed an 18hp Patton Pak refrigeration unit with a heat recovery unit.

The heat recovery system on the Patton Pak puts water into the hot water cylinders at about 50 degrees Celsius, meaning a lot less power is needed than if the water was being heated in the cylinders from cold and it represents a major saving.

The Tru-Test group of companies is one of the world’s leaders in farm technology and offers the farmer a range of very advanced services, including the herd management system Fonterra have chosen for Kapuni 3.

Keeping track

Each cow has a Tru-Test electronic identification tag in her ear that enables the farmer to comply with the mandatory NAIT scheme by keeping track of her throughout her life – and beyond for that matter – and is an invaluable tool in herd management.

Tru-Test scales in the exit race record each cow’s weight against her EID as she leaves the dairy. The valuable information is used with Tru-Test’s MilkHub Herd Tracking system for such things as monitoring herd health and determining feed regimes.

The Tru-Test MilkHub Autodrafter drafting gate in the exit race is also linked into the MilkHub Herd Tracking system and to an overhead display and a console in the pit.

The farmer just needs to put in the EID number of any cow he wants drafted and she’s automatically directed into a side yard for later attention.

The Autogate can also be operated from an Apple or Android mobile phone so animals can be selected at any time and from anywhere.

Installing the GEA and Tru-Test systems is demonstration of Fonterra’s push for efficiency in the dairy, but staff needs were not overlooked either.

As a part of their commitment to their worker’s conditions and comfort, Fonterra had local plumbers GJS NZ Ltd install a toilet and

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GEA Milfos swing arms.

The GEA iCONVERTER aquaCHILL.

wash facilities in the dairy.

Installing these facilities for staff in a dairy is exactly the same as in a home, and the same regulations apply, meaning they’re required to be plumbed separately with their own dedicated septic tank and soakage isolated from the dairy’s effluent system.

Effluent design

So it was a registered plumber for the human waste, but the dairy waste was a different matter and needed a different type of professional – Agfirst Engineering Waikato and Steelcon Construction.

KAPUNI 3

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Coast & Country

ID tags track cows throughout their lives Tru-Test’s MilkHub scales and Autodrafter drafting gate.

The Agfirst Engineering Waikato’s effluent separator.

Tru-Test’s Milk Hub in-pit controls.

Fonterra engaged Davieth Verheij from AgFirst Engineering, an accredited effluent design company to design, supply and build a new effluent solids separation and green water recycling system.

AgFirst Engineering designed, supplied and built the complete system with sub-contractors Coastal Agri Services, Opunake and Steelcon Construction, Matamata.

“The key design considerations for this effluent system was to minimise water-use in the dairy and have the ability to irrigate dairy effluent through the Kapuni factory wastewater system,” says Davieth. “This needed to be achieved with a reliable but simplistic system.”

Agfirst achieved this with a rotary drum separation system to remove solids from the effluent before the green water is passed to the holding pond.

The rotary drum separation system was chosen because of its high flow capabilities, low power consumption and low maintenance.

As the effluent passes through the system the solids are filtered out and dropped into a bunker to be later spread on pastures or crops.

This enabled the existing pond’s working volume to be maximised and the green water to be pumped back to the yard for washdown via the backing gate.

Steelcon Constructions used high-strength concrete for the construction of an oval holding sump – an oval shape makes stirring efficient and prevents any solids build-up – where the effluent is received from the yards.

Then they built the solid waste bunkers with prefabricated con-

GEA Milfos milking plant.

crete panels. Finally, they installed a child-proof fence around the sump to ensure the job is fully compliant with health and safety standards.

No more wrangling

This dairy is all about functionality. Out in the yard there’s a piece of equipment which doesn’t need electronics or computers – and ticks all

Fonterra’s boxes for efficiency and safety for both worker and cow.

A Wilco and Waverley Wrangler hoof trimming press.

The Wrangler came about nearly 20 years ago when young sharemilker Wilco Klein Ovink invented a safer way to treat cow’s legs and hooves by using a system of slings and ropes to manually, but easily, lift and restrain each leg so cows’ hooves can be worked on accurately and safely.

The Wrangler does away with the old wrestling match with each cow and all the inherent dangers of being kicked or trodden on.

It reduces stress levels in cows as well, so it’s not surprising it’s a piece of equipment found in many yards now and richly deserves to be there.

Today, Wilco and his crew are kept flat out in their Whakatane factory

satisfying the demand – no more milking cows for him.

In most respects this dairy is fairly standard, but Quintin reckons it has one unique quality – it’s azure blue roof and flashing is the closest colour they could get to Fonterra blue.

This makes for an interesting company ID. As project manager, Anne is happy with the dairy created.

“All contractors selected produced a quality job for us, and in a timely manner. Our target date was the December 1, 2013, and the first milking actually occurred on December 8, 2013.”

By Graeme Dobson

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Page 10

AFT TRUST

Coast & Country

When three small farms become one

By Helen Wilson

Being born in Taranaki to dairy farming parents, there was always a likely chance Donald Anderson would be a dairy farmer himself.

As a young man he spent time working on oil rigs in the North Sea, saved his wages and came back to Taranaki and worked his way up to owning several dairy farms.

“After sharemilking for several years, my wife Maree and I started with buying the original block off my parents when they retired and have since added to our dairy farm business.

“We enjoy the challenges of dairy farming and I think the future looks bright,” says Donald.

His philosophy is “low cost, low risk, high profit dairy farming with return on capital being the key drivers”.

The No. 2 dairy farm at Rahotu, near Opunake, is an amalgamation of three smaller farms.

The first one was acquired in 1982, the neighbouring one in 1994 and the last one in 2012. This combined farm makes a good size dairy unit of 200 hectares milking 450 cows.

The three original farms all had small dairy sheds on them, which were still being used, but it was time to build a new, more efficient dairy.

Volcanic lahars

The farm sits close to Mount Taranaki and this attracts rain, so during the 2012/2013 drought Donald and Maree Anderson’s farm was still growing grass.

The contour of the land is flat to rolling, interspersed with small mounds called lahars, formed from previous volcanic eruptions.

Farm owner Donald An derson in the circular yard.

Donald had built a 50-bail rotary at one of his other farms in 2009 and was very impressed with its performance, so he decided to use the same builder, Kodesign, which is the dairy shed branch of G.J Gardner Homes in New Plymouth.

“I wanted the same standard plan as last time, without any bells and whistles. The difference is this one is a 44-bail rotary and the platform spins in the opposite direction to suit the new races, and so the cows don’t have to cross the tanker track.

“The walls are made from concrete panels with refrigeration panels on top. The roof is also made from refrigeration panels, which keeps the noise down and keeps it cool in the summer and warm in the winter. They are

AFT Trust

The Kodesign rotary dairy shed at Rahotu. low maintenance and easy to keep clean. So it is cows in, cups-on, cups-off, teat spray, cows out, simple,” says Donald.

The new dairy shed is open to the west as the heavy rain usually comes from the north and the cold weather from the south.

Trusted inventors

Eltham company Hotter Engineering are the inventors of the rotary platform and Donald used them again for this new dairy.

“They are the experts and the other platform is still going well,” says Donald.

DeLaval milking machines have proved their worth during the last 30 years, so were the obvious choice this time.

“They are reliable and provide an excellent

back-up service. It is a standard no-nonsense milking system with automatic cup removers without retention arms, which is easy for staff to use,” says Donald.

“AFT Trust chose a PR1500 rotary platform with a standard DeLaval Milker. It was the first one of this type installed in Taranaki. It is an open-type bail in which DeLaval’s range of automated products, such as an automatic drafting system, can be installed at a later date,” says DeLaval Ltd milking systems district manager Bruce Battersby.

“It is a very simple and effective milk harvesting solution for this farm.”

Michael Bloemen Engineering from Kaponga welded the pipe rails in the circular yard and provided the two backing gates.

RuralContactors NEW ZEALAND

Hotter engineering M a n u f a c t u r e r s o f q u a l it y r o t a r y c o w s h e d s C N C L a t h ew o r k ~ C N C P r es s br a k e ~ R o bo t W el d in g ~ S t r u c t u r a l S t eel

Tel: (06) 764 7059 ~ Fax: (06) 764 5192 www: agritechnz.co.nz ~ Email: admin@agritechnz.co.nz 2 Collingwood Street ~ Eltham P roud winners of the Wes tpac/T aranaki C hamber of C ommerce B us ines s V itality Medium B us ines s Award 2005

AFT TRUST

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Low cost, low risk, high profit dairying Michael Bloemen has been building dairy shed yards since he was 15 years old and has had his own business for the last 16 years. “I also do general repair work, but dairy shed yards are the main part of my business,” says Michael.

Refrigeration in AFT Trust’s other rotary dairy shed was supplied by Tru Test’s Dairy Technologies Services – and with the excellent service and product Donald decided to install the same system. The refrigeration unit chills the milk to the required temperature before going into the vat and retains the temperature until tanker pick-up.

Fencing in rhythm

Building on a new site meant rearranging the fences for easy entry and exit of the cows. Pungarehu company Krutz and Associates can build a one to eight-wire fence or a deer fence. Merv Krutz is the main fencer and his wife Glenda is the ‘gofer’ but also hammers the insulators into the posts

when required. They’ve been in business for nine years.“It was a bit of a challenge here, as we had to take the lahars into account.

“On occasions, we had to use a rock spike to make a hole in the underground rock before putting in the post, to keep them upright,” says Merv.

“It takes a bit longer but you get into a rhythm. We fenced off the new raceways and the effluent pond.”

Agricultural spraying, such as gorse and fertiliser spraying, is the main part of their business as well as fencing.

“We use quad bikes and trailer sprayers, which are more suitable for the hills. We can go where the bigger vehicles can’t and being lighter there is no damage to crops,” says Merv.

The AFT Trust No. 2 Farm at Rahotu employs a variable order

The DeLaval milking clusters.

sharemilker plus one other full-time worker.

Building this rotary dairy shed, farm owners Donald and Maree Anderson have kept it simple by using contractors they know and trust; and can rely on.

By Helen Wilson

A DeLaval rotary dairy shed.

Farm owner Donald Anderson, and fencer Merv Krutz

The double backing gates made by Michael Bloemen Engineering.

The rotary platform supplied by DeLaval.

The lahars formed by ancient volcanic eruptions.

TARANAKI’S PREMIER DAIRY SHED SPECIALIST S “ EVERYTHING ELSE IS A COMPROMISE . .”

ROCKY HAWKE | (06) 769 6512 | 0274 431 704 | rocky@kodesign.co.nz

CORRIGAN

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Coast & Country

Young love for family farm Twenty-two-year old Josh Corrigan is a young man who had to step up to the mark and take over the running of the family farm when his father became ill.

A great team: Carly Muggeridge, Josh Corrigan and his mother Fiona Corrigan, Hamish Thomson from DeLaval, Nick Callingham from Tru-tests Dairy Technology Services, Wonder Minerals sales representative Wayne Trethewey, Central Silo Systems Ltd’s Sean Curry, and Paul Gibson from DairyPro Hawera.

Discussing the merits of swing arm cup removers, Hamish Thomson from DeLaval, farmer Josh Corrigan and Paul Gibson from DairyPro Hawera.

e ute.

th joy a ride in

s en The farm dog

Corrigan The 34-aside herringbone dairy shed.

The second eldest of 10 children and the fourth generation on the farm, he’s taken on the challenge and with the support of family has increased the area of the dairy platform, increased herd numbers and production – and just built a new 34-aside herringbone dairy.

When New Farm Dairies visited in February he was also looking forward to getting married to Carly Muggeridge in 25 days’ time.

The farm is on Whakatau Rd near Hawera in Taranaki and has 142 hectares in dairy and 70ha in sheep and beef. Josh’s parents, Duncan and Fiona Corrigan, moved to Whakatau in 1991 with three children. Sadly Duncan died in October 2012 just after signing the contract for the new farm dairy. The farm is now in a trust with Josh as manager and his mother Fiona overseeing the operation of the farm. Older siblings lend a hand, as well as cousin Chris Reed; and Josh’s fiancé Carly Muggeridge is an “all-rounder” helping in the dairy and the house.

The farm had an old 18-aside herringbone shed which needed to be upgraded with an increase in herd numbers.

The planning started in September 2012 and the project was completed during January 2013.

“We decided to build a 34-aside her-

ringbone, as it was the most cost-effective option. We chose a DeLaval milking system for its reliability and it was installed by DairyPro Hawera,” says Josh.

Choosing reliability

DairyPro Hawera managing director Paul Gibson, who is the agent for DeLaval in South Taranaki, says he showed Josh and Fiona all the different options which were available “and they chose DeLaval for reliability and after sales service”.

“The plant has swing down arms, which give excellent cluster alignment, and the automatic cluster removers are incorporated into the swing arms.

Paul says swing arms make plenty of room for the milkers to move in the pit, being ideal for herd testing.

“The jetters swing down for ease of use and the vacuum system has a variable speed drive which gives maximum power savings and minimum noise,” says Paul.

Hamish Thomson is the milk quality specialist for DeLaval and takes care of after-sales and hygiene requirements in South Taranaki.

“We have an excellent back-up service and we are always available when required,” says Hamish.

Josh says the DeLaval DSG3 automatic drafting system is a real time-saver. “I can programme my drafting requirements weeks ahead and it’s all done saving labour, money and time.

“The drafting gate and milking plant can be integrated with the milk meters for accurate drafting of low production or sick cows.”

Bridge St, Eltham

Address 57 Mihaere Drive, Roslyn Palmerston North, 4414 Email

centralsilosltd@xtra.co.nz sean@centralsilosystems.co.nz bernie@centralsilosystems.co.nz

Phone (06) 358 5805 Fax

(06) 358 5806

Mobile 027 275 6575

CORRIGAN

PH 07 578 0030

Page 13

New dairy puts farm in good stead Nathan Gray, who is a grandson of D.R Gray Ltd from Hawera, applied a special paint coating to the pit walls and milkroom walls. This gives a durable, hygienic surface which is easy to keep clean. D.R Gray Ltd has been painting buildings in and around New Plymouth and Hawera for more than 50 years.

The refrigeration unit was installed by Tru-Test’s Dairy Technology Services based at Normanby, which is close to Whakatau Rd. “The double-plate heat exchange chills the milk to 18 degrees Celsius before it goes into the vat and returns the warmed water to the hot water cylinder reducing hot water heating costs,” says DTS refrigeration technician Nick Callingham. The refrigeration unit for the two vats chills the milk to below seven degrees Celsius within three hours after milking. “It does this easily. The polar wrap on the vat cuts the chilling time too,” says Josh.

Tru Test’s DTS also builds stainless steel tanks for Fonterra, as well as providing an on-farm back-up service.

A robust system

Corrigan’s dairy shed has been fitted with a Central Silo Systems Ltd in-shed feed system. This is an extremely robust system made to last, as it has standard galvanised drop pipes instead of PVC and a fully galvanised steel frame to support the continuous stainless steel feed trough. The meal dispensers are also galvanised to help protect them from being damaged.

Central Silo Systems Ltd’s Sean Curry, who operates the family-owned business with father Bernie Curry and wife Paula,

says their clients have the option of three different types of dispensers to suit their requirements and we also offer the option of stainless steel bolt-together or fully TIG-welded feed pans, the latter giving the option of adding a molasses injection system.

“We installed a 16 tonne silo at this dairy shed but also offer larger storage silos and full on-farm feed mills if required.

“The dry feed is then augured from the silo into the meal dispenser and then directly to each cow. We are finding in-shed feeding is becoming more popular with dairy farmers in rotary and herringbone dairy sheds.

Sean says Central Silo Systems Ltd has its own installers and service engineers “so we can provide continuous after sales service to our clients when they need it”.

Josh says Michael Bloemen Engineering from Kaponga did all the pipe work in the yard, and the AB area rails and installed the bail gates.

“The middle pipe on the outside rails carries water to keep the yard clean during milking. Their price was very competitive, they were efficient and easy to deal with,” says Josh.

calcium and magnesium for milk fever and grass staggers; and this year topped the cows up with liquid copper and lime flour. “The calves looked really healthy this year and that’s partly due to making sure the cows have all the minerals they require,” says Josh.

Wonder Minerals also provide bloat oil for troughs, for prevention against the digestive disorder.

“We mainly supply the dairy industry but also supply cleaning products for other businesses,” says Wayne.

Next season Josh and Fiona intend to increase the herd to 400 cows on a grass-based system with meal to boost production. The sheep and beef animals will be kept for the time being, to tidy up the gullies scattered around the farm. It only takes two people about 45 minutes to milk now and can be managed by one person if necessary. They’re aiming to do 115,000120,000 kg/ms this year.

The family farm is in good hands, with a committed young farmer such as Josh and thanks to his supportive family.

Central Silo Systems Ltd supplied the silo.

Robust feeding system by Central Silo Systems.

By Helen Wilson

Wonder-full minerals

Wonder Minerals has been around for more than 20 years and has been associated with the Corrigan’s for the last five years. “We look after animal health and use preventative measures rather than treating the animal once it is unwell,” says Wonder Minerals sales representative Wayne Trethewey, who is based at Eltham.

During calving Josh gives the cows

LYNDON HARROWS AND ENGINEERING LIMITED

The DeLaval milking plant.

Nick Callingham, from Tru-Test’s Dairy Technology Services.

Page 14

HOCKLY PARTNERSHIP

Coast & Country

When a scribble becomes reality This is just the flexibility Craig wanted, as he could picture what he desired in a dairy shed – and it had to be child-friendly with both his farm workers and himself having young children.

Proud dairy farmers Deanne and Craig Hockly.

“It was a huge learning curve for both of us, as this was Johnny’s first new build dairy shed since starting his own company.”

Johnny reckons he must have done a good job, “as I now have lots of requests from other dairy farmers ‘to build a dairy shed just like Hockly’s’”.

Craig Hockly is the third generation to take over the family farm just out of Hawera in Taranaki.

“My father told me I had to have a trade, so I worked in Hawera and became a qualified furniture-maker.

“My parents bought more land and I decided to come home on the farm. Dad had a year off and employed a couple to milk – and I had to start at the bottom as the farm hand,” says Craig.

When the couple left Craig worked with his parents on the farm. Craig is married to Deanne and they have two children, aged 10 and seven. Deanne combines farm office work, calf-rearing and family commitments.

Since acquiring more adjoining land and increasing the herd they outgrew the old dairy shed, so built a new 60-bail rotary with all the latest features.

Matt Cleaver has been an excavating contractor around South Taranaki for many years and his knowledge was invaluable when making sure the site was “just right” for the new dairy shed.

“It took three days to prepare the site. I

worked in with Johnny Neil, the builder, to make sure the drains were in the right place,” says Matt. He also tidied up the site by replacing the topsoil and landscaping the area.

The Waikato Milking Systems plant is a 60-bail Orbit concrete rotary platform and milking machine, kitted out with a full Afimilk automation system. Waikato Milking Systems and its dealers are the only suppliers of Afimilk herd management technology in New Zealand.

“The Orbit platform is designed and manufactured for efficient milking of large herds. Known for its strength and engineering integrity, it integrates perfectly with technology enhancements from Waikato Milking Systems,” says WMS lower North Island sales manager Brent Crothers.

The new generation technology the Hocklys selected from the WMS range includes SmartSPRAY, an automatic teat spray system for rotaries that ensures optimal teat coverage and reduces the amount of spray used.

They have SmartPULS, a digital pulsation system that works in harmony with cows to open and close the liners consistently and dependably every milking, providing optimal milking performance.

Before we get to know your farming business, we’ll get to know you.

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DESIGN – SUPPLY – BUILD

BailGates is an integrated electronic bail retention system that keeps cows on the platform during milking if they need to go round a second time.

The Afimilk Herd Management System ensures the Hocklys get the information they need to make effective animal management decisions in a timely way.

Afimilk’s Herd Management System provides farmers with useful and user-friendly information about individual cows in the herd, including milking efficiency, animal health, breeding, feeding and culling.

The Afimilk options include AfiWeigh, which automatically identifies and weighs cows as they walk over the weighing platform and stores the data in the Afimilk database, enabling estimation of dry matter intake and monitor the animals’ stress and health.

Smart thinking

ASB Bank Limited PPU45677

“A lot of pieces of paper with scribbling all over them passed between me and Johnny Neil, the builder, when planning this dairy shed. And I have to say he was always flexible and took the changes in his stride,” says farmer Craig Hockly.

Deanne Hockly checks data on the computer.

PH 07 578 0030

HOCKLY PARTNERSHIP

Page 15

Everyone wants a new dairy like the Hockly’s The Hocklys also have AfiSort, a powerful management tool that automatically drafts cows based on selected criteria. Their AfiMilk MPC milk meters provide reliable milk yield data that supports productivity, feeding and breeding decisions. Their Afimilk Pedometer Plus system collects data about animal activity, aiding decisions around health and fertility.

Bird-proof

Builder Johnny Neil has been involved in building dairy sheds for many years, lives close by at Okaiawa, and has now formed his own company.

“Craig and Deanne’s dairy shed has a widerspan than normal to allow more room between the platform and the walls. We had to take into account the proximity of the coast and salt spray. The roof is colour steel max. It has been bird-proofed with shade cloth curtains across the front of the platform,” says Johnny.

The walls have all been sprayed with a special hygienic coating by Fritz from Surfatex. The shiny surface makes it easy to keep clean and looks good too.

Mark Ward is the South Taranaki area manager for FIL and set up a wash programme for the dairy shed. “We set up an individual wash programme for each client. In the Hockly’s dairy it is all automated so there is no handling of chemicals. It is programmed to do an acid detergent wash and a rinse after each milking.

Craig hasn’t had any grades, so it is working brilliantly,” says Mark.

FIL also supply the teat spray.

Central Silo Systems Ltd installed the in-shed feed system, which is controlled by the plat-

have the most gates in any dairy shed yard we have built”.

He’s patented his High Runner backing gate for rectangular yards in herringbone and rotary dairy sheds. “It is self-aligning which means it is smooth running and jam free,” says Michael.

“They did a great job making sure the holding pens and gates were exactly how we wanted them,” says Craig.

Hockly Partnership

Gaining power

forms computer system to individually feed each cow.

The complete feed system comprises of two separate 110mm feed lines auguring from each of the two 16 tonne Valco North American manufactured meal silos, giving the ability to feed two separate meal products, says Central Silo Systems Ltd co-owner Sean Curry “Central Silo Systems complete in-shed feed systems are built for extended service life and the company provides a full parts and after-sales service back-up from their Palmerston North premises.”

House alarm

Craig says Tru-Tests Dairy Technology Services did a great job installing the refrigeration. “It included a ‘Tempro’, which has an alarm in the house which lets us know if there is a problem with the refrigeration.

The heat recovery unit, installed by Tru Test’s Dairy Technology Services, is made from stainless steel for rust protection, and reduces the temperature of the milk to below seven degrees Celsius within three hours of milking.

“The heat recovery means the warmed water is recycled into the hot water cylinder, saving farmers hot water heating costs,” says DTS refrigeration technician, Nick Callingham.

Michael Bloemen of Michael Bloemen Engineering at Kaponga reckons: “Craig and Deanne

Powerworx is a Powerco-accredited lines division of the Obertech Group, which has its main office in Hawera and builds overhead and underground services for customers in the Taranaki region.

Powerworx contracting division manager Bruce Wilson says the Hockly’s dairy shed has its own transformer because of all the new technology in the dairy shed.

“It ensures less interruptions if there is an outage. The overhead lines carry 11,000 volts from the road and then go underground to the dairy shed,” says Bruce.

“It’s much more reliable having your own transformer and it is becoming more popular with larger dairy sheds.”

Having a good relationship with the bank manager is always advisable when contemplating a project such as this one. “Our ASB bank manager at Hawera is Sami Werder and he is very supportive especially during the drought, says Craig.

“He went over our budget and could see this was a viable proposition. Without his and the bank’s support, this dairy shed would not have happened.”

Milking time has been reduced to two hours from cow-cupping to the cows exiting, compared to three hours in the old shed.

By Helen Wilson

The crew who worked on the dairy shed: Farmers Craig and Deanne Hockly, Powerworx manager Bruce Wilson, Tru-Tests Dairy Technology Services refrigeration technician Nick Callingham, Central Silos Systems co-owner Sean Curry, Matt Cleaver, builder Johnny Neil and Mark Ward from FIL.

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Page 16

DAVIDSON

Coast & Country

Ditching wool for milk at Pohangina Valley Bill Davidson, who was a sheep and beef farmer at Patea in Taranaki, came to the Manawatu in 1971 with his family and bought a farm in the Pohangina Valley near Ashhurst.

“We talked to a lot of people and gathered a stack of pamphlets and came home and sifted through them,” says Bill.

After analysing the data the figures stacked up, so the next stage was to obtain consent for change of land use from Horizons Regional Council. Once consent was granted, planning the new dairy shed started in earnest.

He married Yvonne in 1974 and they continued to farm sheep and beef until their son Robbie approached them two years ago, Double-up dairy with a proposal to convert the farm Bill and Robbie briefed Brett into dairying.

The exit end of MacDougall, of MacDougalls Robbie had completed a of Palmerston North and the new dairy. degree in applied sciences at Pahiatua, and the DeLaval Massey University, worked agents for Manawatu, as in the United Kingdom to what they required in for two years, and came a dairy shed. back to New Zealand to And along with Hummanage a sheep and beef phries Construction of farm in Taranaki and then Palmerston North, they went onto a sharemilking all came up with a concept job at Bell Block. for the Davidson’s approval.

“Robbie and his wife, Sher“Instead of a conventional rilyn, had 12 months to go on herringbone dairy shed, we their sharemilking contract when decided on a DeLaval 18-aside Robbie suggested we convert to dairy and they could be the sharemilkers,” says Bill. double-up system,” says Robbie.

“It has two rows of cups, which is equiva“I wasn’t keen to start with but when we lent to a 36-aside herringbone but the pit is went to the national Mystery Creek Fieldays shorter and I’m able to milk 300-plus cows that year everything seemed to be related to on my own,” says Robbie. dairy farming.

one. It has the upgradeable technology and “It takes about two hours from getting the has the capability of having the latest cows in, to locking them away.”

The effluent pond, DeLaval herd navigator, which A parallel first is like an on-farm laboratory built by Blackley This is the first DeLaval installed when available,” says Construction.

Parallel milking parlour in the Brett.

North Island. “This system Kane Barry, project manager was the only way to guarfor Humphries Construcantee that one person could tion from Palmerston North, manage 300 cows on their worked with MacDouown,” says Brett. galls on the design of It is a low line milking system the dairy shed. with a lower milking vacuum for The original better udder health. One slow cow in plans were the row doesn’t hold up the milking and changed slightly it’s easier to check on cow health, as the to incorporate milker walks past the cows. an extra yard The plant has milkand a gable The DeLaval ing point controllers roof. They double-up (MPCs), automatic always take the milking system farmers requirecup removers, duo with a shorter ments into vacuum function and pit area. also calculates the consideration milk yield per cow, and will make any changes to which feeds back their standard dairy shed plans. to a central processor – so Robbie knows Sharemilker Robbie Davidson, exactly what each cow with his father Bill Davidson, produces. who owns the farm and Brett “This DeLaval plant is MacDougall, managing director just a step down from a robotic of MacDougalls.

PH 07 578 0030

DAVIDSON

Page 17

Parallel parlour with one man handling 300 cows

Cows’ entry in the Davidson’s new milking parlour.

The internal walls of the dairy shed have been sprayed with a hard-wearing resin paint by Surfatex for easy cleaning and it brightens up the area.

Utilising waste energy

Tru-Test’s DTS Milk Cooling Solutions installed a PZB 1300 13hp refrigeration unit to assure the best milk quality.

Tru-Test’s DTS Milk Cooling Solutions’ lower North Island area manager Tim Rix says milk needs to be cooled more quickly to comply with the new regulations coming into force in 2016.

“This unit has a vertical air discharge, which is much more efficient condensing for quicker cooling,” says Tim. It also has a brazed plate heat exchanger that utilises waste energy, which is a by-product of the cooling process.

The water goes into the cylinders at about 50

degrees Celsius and is then heated to 85 degrees Celsius and used for washing the plant.

“This is a huge cost-saving in power for the farmer,” says Tim. The milk vat was also supplied by Tru-Test’s DTS and made at their factory at Normanby in Taranaki.

An optional extra is a Tempro, supplied by Tru-Test’s DTS, which is a remote milk temperature display in the pit.

It continually flashes up the milk temperature in the vat so any problems can be dealt with quickly, stopping the milk spoiling.

DTS provide a full follow-up service with either a Tru-Test’s DTS technician or a recommended independent refrigeration contractor.

Robust meal feeding

Central Silos Systems Ltd at Palmerston North supplied and fitted a heavy duty, robust meal dispenser with a high ultra violet rating in the new dairy shed.

Central Silo Systems’ Sean Curry says the dispenser has been designed specifically for the dairy industry.

“And we use galvanised dispensing pipes,

rather than PVC, for increased added protection and they will last longer,” says Sean. that. The farm The continuous has large stands feeding pan has been of mature trees, which DeLaval’s TIG-welded and stainwe worked to save as opposed to less steel bolted for added teat sprayer wiping them out and starting at cow exit. strength and longevity. again,” says James Palmerston North’s Blackley Blackley Construction Construction rural contract mancame back in March and ager James Christensen supervised built the effluent pond, all of the site works, including the which is fully compliant dairy shed, herd home, effluent with a plastic liner with pond and all of the farm races. council-required leak “Bill booked us in six months in detection system. advance and we started in DecemThe DeLaval cups ber 2012,” says James.

Sheep roaming fit on the jetters for Blackley Construction has been doing There are still a few sheep on cleaning. the farm “to clean up areas where work for Bill for 35 years and were the obvious choice for the dairy conversion project. the cows can’t go”.

“Luckily for the Davidsons they had on-site Although Robbie and Sherrilyn are the sharepit metal, which saved them a significant milkers, Bill takes a keen interest in the farm amount of money on the races and building and helps out when necessary. foundations.

“I haven’t actually milked a cow yet – but “Bill and Robbie had a farm plan of where dairy farming leaves sheep farming for dead,”

By Helen Wilson everything was to go and we just worked to says Bill.

Beams & Timber Direct Ltd (BTD)

Page 18

MASSEY

Coast & Country The cow barn from the front of the farm.

Uni leads way in testing farm methods is 232 hectares effective and is part of the Massey campus in the Manawatu. Milking 650 cows, it’s a traditional spring calving operation.

“The project’s overall objective is to increase productivity while reducing the environmental footprint,” says Mike.

Massey University’s No. 4 dairy farm is now home to a large farm systems trial that’s part of a nationwide research programme called Pastoral 21.

Funded by DairyNZ, Fonterra, Beef + Lamb NZ, Dairy Companies Association of New Zealand and Ministry of Business, Innovation and Employment, it includes three other regional farms: one in the Waikato, one at Lincoln and the other Massey No. 4 cows showat Telford in Otago. ing good condition.

Professor Mike Hedley is the project leader and the research the 2013/2014 season. The funding will see is to ascertain whether partially standing cows the trial run initially for three years, when the off pasture using a housing facility is a system results will be collated and may continue for that can increase on-farm productivity, while longer if research funds become available. reducing nutrient losses.

The No. 4 dairy farm used in the research The comparison trial began at the start of

Standing cows off

“Each region has its own focus; here in the Manawatu we have fine-textured clay soils, much like other areas such as Southland and Otago.

“In previous research, by standing the cows off for some of the time – particularly during late summer and autumn – we’ve noticed a reduction in nitrate leaching.

Standing cows off during wet winter and spring months will also lead to less treading damage, which has an impact on increasing subsequent pasture growth, says Mike.

The herd has been split in two: one as a standard grazing herd, using the existing feed pad, and the other herd is a ‘durationcontrolled’ herd.

These cows are grazed as much as possible

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on pasture, but stood-off in a housing facility during critical times.

Supplements are fed in the house, as they are to the standard herd on the feed pad.

Controlled herd

The cows are a mixture of Friesian and Friesian crossbreds. When New Farm Dairies visited in June, the cows in the durationcontrolled herd were in-calf, had plenty of condition on them and were being break-fed long lush pasture.

Mike says from February to May one group is managed as a duration-controlled herd on one side of the farm.

“The cows are put out to graze for four to five hours after milking and then taken off the pasture to the cow barn to receive supplements if needed.

“In the winter, the weather and soil moisture plays a large part in determining how long we leave the cows on the pasture – the wetter it is, the more treading damage there will be.

Mike says Massey has several weather monitors to supply data as well as forecasts and “looking out the window”.

MASSEY

PH 07 578 0030

Page 19

Cow barn could improve pasture, cow health and production

It’s early days yet to start comparing results, but the farm systems research is monitoring soil condition, nutrient loss, pasture growth and quality, cow production and condition, and cow health such as mastitis and lameness.

Comparing the two systems will also take into account labour and feed costs and the overall economic performance.

Cow barn

There are monitoring stations in the cow barn and in the paddocks, which monitor the heat load inside and outside.

“Our role as researchers is to quantify how the use of a cow barn can be implemented on the farm to improve pasture quantity and quality, cow health – and of course, production,” says Mike.

Dairy housing consultant and expert Harmen Heeson was instrumental in ensuring the design and layout would work for the intended outcomes at Massey No. 4 dairy farm.

“I provide the builder [Cowhouse Construction Ltd] and the client, in this case Massey University, with expert advice and support for the project, making sure it will work and be cow wellbeingfriendly,” says Harmen, of Cowhouse Ltd Consulting.

A big part of the design expertise was the integration of all existing systems with the new cow barn.

It had to fit in with the existing rotary dairy shed, silage bunkers and another effluent pond for the rotary dairy shed and allow easy cow movement between the buildings.

The cowhouse can accommodate 400

cows and Technipharm from Rotorua provided the fit-out equipment.

Soft sleeping

This included approved Polysoft cow mats for cow comfort, the stall guidance system, cowhouse separation gates, ventilation curtains and the cowbrush and scraper system.

It doesn’t take long for the cows to work out The cows happy in the cow barn. sleeping on something soft is far more comfortable than hard concrete. it is used often. The cowhouse is divided in two, with There are two large roller brushes installed so the cows can give themselves stalls down each side and a wide laneway in the middle where the supplements and harvested grass are fed out. a back scratch when they feel like it and

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MASSEY

Coast & Country

University farm tests effectiveness of housing facility The well-used back scratcher.

The lane-way is wide enough to accommodate a tractor, and at the front of the building there’s a turnaround circle for the tractor.

An automatic scraper system has been installed to efficiently scrape away the effluent, which then drains into the new effluent pond.

New methodology

Palmerston North company Blackley Construction Ltd won the tender with Cowhouse Ltd to construct the large effluent pond.

long the cows are housed for.

Blackley Construction Ltd It will be emptied about four-six times a rural contract manager James year and spread back onto pasture to replace Christensen says the effluent nutrients not being deposited as dung and pond had to be compliant urine from the cows. with regional council standards.

Up for debate “And because the soil type Blackley Construction Ltd also caron-site is Tokomaru silt loam, ried out the site works to prepare the which is clay-based, we were building platform, as well as removing able to use the in-situ and re-compacted clay to build a compliBlackley Construction’s rural contract manager ant pond, saving James Christensen checks the effluent pond. the cost of a plastic liner,” says James.

“It is the first effluent pond in the Manawatu to use this methodology and it’s 10 times more impermeable than council requirements.”

A rigorous testing regime was implemented to ensure all re-compacted clay would meet permeability testing requirements.

The effluent pond has a capacity of 5000m3 and the amount of effluent produced depends on how

a stand of mature pine trees so the required infrastructure would fit.

Farm Supplies Central reinstalled the original effluent line.

Whether to house cows or not is always a subject for debate when dairy farmers get together.

Sometimes it depends on climate, availability of land or soil type.

The research Mike is leading will prove invaluable for dairy farmers to make informed choices about housing cows, based on the economic and management outcomes of the Pastoral 21 research programme.

Thanks go to Doctor Christine Christensen, who is part of the research programme, for showing New Farm Dairies around No. 4 dairy farm.

PH 07 578 0030

MASSEY

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Page 22 C&F Industries steelwork over the DeLaval scales and drafting gate.

The Weatherstone’s forebears settled at Tuhitarata in South Wairarapa in 1843 – yes, that’s 171 years ago.

Rotopai, the original dairy operation, began back in 1931 with about 100 cows and has grown exponentially.

Today Bryan Weatherstone and son Stewart, who is farm manager, milk 2600 cows off 1350 hectares, which extends from seven kilometres of river frontage all the way to the skyline.

In 2000 they put in a 60-bail rotary dairy, but more farm expansion overstretched its capacity – so last year they built a new 80-bail rotary to take some of the load, by milking 1500 cows.

Return customer

Pat Finn from C&F Industries designed the other dairy and the result was excellent – so it was logical for the Weatherstones to sit down with him and design the new one.

Pat sorted out all the permits and supplied

Rotopai’s ruthlessly efficient dairy

the materials; then when it came to building it became a cooperation between C&F Industries and Paul Bashford, from Bashford Construction Ltd. But first local earthmover Malneek Contractors was needed for the earthworks. Lee Malneek did all the site-work, including preparing the tanker track, building site and digging the ponds.

“Lee’s done a lot of work for us before – all the irrigation lines, races and the underpass.

His bulldozer driver, Alan Pilcher, in particular, is excellent,” says Bryan.

“They started with the green field,” says Paul.

“I came in with Pat and put the pegs in the ground; then they dug out what was needed to be dug out, got the metal they needed for the foundations and prepared the whole thing ready for us.”

Heaps of room

Once the earthworks were ready Paul did the footings and concrete work and organised the

The front of the Weatherstone dairy.

DeLaval Bails.

blockwork. Then C&F Industries manufactured and erected all the steel-work, pipe-work and the backing gate in the 16 metre radius yard, and designed and built the effluent system.

Paul then put the roofing and cladding on and did all the finishing.

The dairy is large – at 23m by 35m – so there’s heaps of room around the platform. And what’s slightly unusual is the platform bridge is under the eaves on the ‘side’ of the building.

This allows the roof over the entrance to be low and provide maximum protection from the elements.

Paul was able to incorporate an expanse of clear plastic in one of the high gable ends to provide natural lighting and large sliding doors under it, to provide maximum access and ventilation.

Sliding doors opposite the bridge provide more access and ventilation while the vats are located under the other gable.

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The complete dairy.

Three generations of Weatherstones, fixed in concrete. space to incorporate storage, office, machines and staff rooms.

Outside, a separate roofed area shelters a vet yard. It’s a neat arrangement that suits any season; and the workmanship is outstanding.

“Paul does mainly high-end residential work and he treated our dairy with the same care he’d use on a million-dollar house – that’s why we got him,” says Bryan.

Plant perfection

Cotter & Stevens Ltd Electrical & Machinery managing director Jim Clark says as the Wairarapa DeLaval agents, his team installed the DeLaval milking plant.

Martinborough-based Cotter & Stevens Ltd also put in all the wiring, plumbing, water pumps and effluent system. In fact once the building was up, they did pretty much everything.

Jim says the Weatherstones have all the best technology available.

“On the DeLaval platform we installed a full

ROTOPAI FARM

PH 07 578 0030

The C&F Industriesdesigned and built vet yard.

Rotopai Farm Central Silo System’s silo and feed system.

Page 23

Farm manager Stewart Weatherstone with his father Bryan Weatherstone; Cotter & Stevens’ managing director Jim Clark and Paul Bashford, from Bashford Construction Ltd.

Cows enter the yard through a foot wash.

Ingenious operation in South Wairarapa ALPRO herd management system that includes automatic cluster removers, milk metering, and blood and conductivity measuring,” says Jim. “Each cow’s milk yield is recorded every day and she’s weighed each time she leaves the dairy. This allows ALPRO to feed her individually with a crushed barley and molasses mix.

“The Weatherstones also have the ALPRO drafting system that lets them manually draft animals either individually or in batches, or the computer can be set to do it automatically.”

The bail gates are also linked to the ALPRO system and only come down if the cow needs to be kept back – either because she’s kicked the cups off, or the computer has detected a problem needing closer inspection.

The ALPRO herd management system is fully DeLaval, so the Weatherstones didn’t have to look at integrating anything else.

“The other dairy is set up with the ALPRO system and it’s been excellent,” says Stewart.

They’re in the process of linking the systems in the two dairies, so cows and staff can interchange as they move around the farm.

It’s also linked to the house so Stewart can work from there.

“ALPRO is also a great help in drying off,” says Bryan.

“It progressively drafts the low-yielding cows and leaves the higher-yielding ones to milk through, whereas in the past we’d dry off mobs that included some that were still producing.

“ALPRO also controls the feed distribution in the bail, that’s saved about 30 or 40 tonne of grain by limiting wastage. In the end, ALPRO’s paid for itself,” says Bryan.

Faultless feed

The system that delivers the feed to ALPRO is a standard CSS Feed Mill and Molasses system, supplied and installed by Central Silo Systems.

It comprises of a 180 tonne Hopper bottom grain silo, SKIOLD Danish-manufactured disc mill and CSS 4500kg Meal Mixer.

The mixer accurately blends ground grain with additives – such as lime flour, magnesium, rumensen etc – before conveying the mix to feed heads inside the dairy where ALPRO takes over.

Central Silo Systems also installed a 36 tonne meal silo for additional storage of grains, palm kernel, dried distillers’ grains, soy meal, or anything else they want to include.

“Central Silo Systems did the other dairy back in 2000. They

gave good service, so we stayed with them,” says Stewart.

Hygiene is high on the list too – there’s even a foot wash for the cows as they enter the yards, which keeps stones and mud out.

The Weatherstones have also put in a state-of-the-art effluent system, designed and built by C & F Industries, which features effluent solids removal by GEA Farm Technologies’ Houle Solutions Agi-pump and slope screen.

GEA Houle Solutions field services technician Murray McEwan says his team specified the size of the receiving sump to allow for three days’ storage – and just in case of accidents, they’ve incorporated an alarm system.

Murray says they supplied an Agi-pump fitted in the sump to agitate and homogenise the raw effluent before pumping it up to a 1.2m by 1.2m slope screen that processes between 300-500 litres of effluent per minute, depending on the thickness. With no moving parts the only maintenance is an occasional wash.

The screen removes the solids before the green water gravityfeeds to a 3500m3 pond lined with a Viking Containment geosynthetic liner.

The solids drop off the screen into a bunker,

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ROTOPAI FARM

Page 24

Rotopai Farm

GEA Houle Solutions field service technician Murray McEwan, with the solid waste bunker.

The effluent pond, with a Viking Containment liner.

Seven pumps shift water from the dairy right across the farm.

Coast & Country

Water aeration unit at work removing iron from the water.

Effluent sump with GEA Houle stirrer and pump.

Happy staff, cows, neighbours at Tuhitarata to be spread on pastures or crops when needed.

Murray says this passive separation system has been in New Zealand for four-five years.

“We’ve got about 60 in now. When it’s used with water recycling it can reduce freshwateruse from 50-70 litres per cow per day to 12 litres – that’s a massive saving.

“The way the regional councils are going with the water-use regulations that’s going to be a very important consideration.”

Preventing crusting

Murray says screening the solids out also prevents crusting “and may do away with the need for an agitator in the pond because there’s no solids build-up – this pond’s been operating for a year and the floating solids in it are negligible”.

Together with Dairy NZ and council, C&F Industries designed the pond to meet both the farm’s needs and comply with all local envi-

ronmental regulations, then passed the data to Viking Containment to make and install the liner.

After Viking welded each joint on-site it was pressure-tested as part of Viking’s quality assurance, then given a 20-year warranty.

Viking also installed gas venting to prevent ballooning, whaling up, from any gas build-up under the liner.

The whole operation was quick and efficient – Stewart says it took the Viking team just three days to complete.

Although much of the effluent system is gravity-fed, the pumps rely on electricity and extended power cuts can be disastrous.

Power insurance

As insurance, Invercargill-based Cow Power Generators supplied a massive 187 kva back-up generator that could run the whole farm if necessary.

The Weatherstones originally went to Cow Power for a generator in the other dairy because they liked the simplicity and reliability Cow Power offered.

Cow Power also gave a very good price on the first generator – so the Weatherstones went back to them for another one.

“We use it once a month just to make sure it’s checked regularly, otherwise probably no one would go near it. But the point is that we’ll never have any shutdown time,” says Stewart.

“Really a generator is an essential on all dairies, they should be compulsory,” says Bryan.

Pond pride

The Weatherstones are especially proud of the oxidation pond they designed with Cotter & Stevens Ltd Electrical & Machinery.

The bore water is very high in iron so they have a unit that sprays it into the air to oxidise the iron.

COTTER & STEVENS Electrical & Machinery

Once the rust has settled out, the water is filtered and UV-treated to make it fit for drinking.

The water pond holds 1.2 million litres – five days’ worth – so there’s no need for water tanks.

The water gravity feeds from the pond to a manifold at the dairy where seven pumps direct it to the dairy, or out across the farm. Like the rest of the dairy, the water oxidation system is a total success story.

The Weatherstone’s pride in their property shows in the whole ambience of the dairy – the way they keep the dairy’s environs so neat, clean and manicured – and the way they look after their staff, even to the point of providing them with breakfast.

They’ve even installed mufflers on the dairy’s machinery, just to keep the neighbours happy.

This dairy has a wonderful feel to it – it’s very user-friendly and outwardly simple, but behind the scenes it’s very complex and almost ruthlessly efficient.

By Graeme Dobson

PH 07 578 0030

ROTOPAI FARM

Page 25

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PANEA FARM

Page 26

Panea

Bob Hill-Rennie prepared the site, including the effluent pond.

Earthworks by Greg Vercoe and Bob HillRennie, and pond liner by Viking.

Looking down the length of the bails

Coast & Country

Built for future There’s one thing about Roger McCosh. He’s been in the business long enough to know exactly what he wants – and it shows in all aspects of his new dairy.

Roger’s new 250 hectare Bay of Plenty conversion and its 40-aside herringbone dairy were near completion in late-June, but it wasn’t quite there yet.

When it’s finished he intends to milk 450 cows, but when New Farm Dairies showed up he was fully concentrated on just having the dairy ready when the first calves drop.

When Roger and a local cowshed expert builder designed this dairy they had one eye firmly on the future by having the pit extended to accommodate 50 bails on each side, so if Roger decides to expand the herd, the cost to the dairy will be minimal.

“The last place I built cost me as much to expand as it did to build the original dairy, so it made sense to put that bit of extra in now,” says Roger.

The property was a sheep and drystock unit before Roger bought it, but it had been a dairy farm about 25 years ago and boasted a dairy built way back in the 1930s.

Unfortunately the technology wasn’t quite up to scratch, so it all ended up in a hole nearby and Roger went to GEA Milfos for the latest in milking machines.

“I went to GEA because they’ve got Milfos.

I’ve used Milfos for the last 30 years and it works well, so when you have something that works why change?

“And I’ve gone with very few electronics, so there’s really nothing to go wrong,” says Roger.

But before he could begin building, he needed to shift a lot of dirt. The farm has a shortage of flat areas big enough to accommo-

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date a dairy and its associated yards and tracks, which meant a hilltop needed flattening.

Roger knew just the man to do this: local man Greg Vercoe. Greg’s normally kept pretty busy contouring kiwifruit orchards and land for irrigators.

In fact, he’s been flat out since the kiwifruit rebounded a few years back – but he had the time for Roger.

“Greg pushed about three metres off the top off the hill and used the fill to make enough flat for the building and for the tanker to turn around,” says Roger.

“He [Greg] did all the heavy work, then Bob Hill-Rennie used his digger to refine the levels, dig the herringbone pit, and put in all the dairy’s drainage and the pipes,” says Roger.

“I got both Greg and Bob in because they’re local, I’ve used them before and they’ve always done a very good job for me.

“Besides, I like to get local contractors from the Te Puke area and support the town.”

Minimising electronics

It was another local company, Te Puke-based Think Water BOP – the local agent for GEA Milfos – that installed the Milfos milking plant.

As he did before, Roger wanted to minimise the electronics in the dairy so Think Water BOP put in mechanical components, such as mechanical pulsators, instead of the computerised systems that GEA Milfos have available.

But there are some extras, for instance the iNTELJET 150 purge system that puts a pulse of compressed air through the milk lines to ensure all the milk is recovered.

Another area where Roger has gone up market is the GEA Milfos walk-through teat spray in the exit race that effectively sprays the teats with teat spray when the cow breaks an infra-red beam as she passes.

There used to be a hill here – but now there’s Roger’s new dairy.

GEA Milfos drafting gate.

The Milfos iNTELJET 150.

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PANEA FARM

Page 27

Roger gets what he wants

Shane Reid, Kelvin Witheford’s apprentice, at work wiring up some of the pumps.

Think Water BOP also installed a three-way drafting gate that’s air-operated from a consul in the pit.

This can be switched to computer operation should Roger change his mind in future.

Kelvin Witheford from Witheford Electrical Ltd installed all variable speed pumps to move the water, milk and effluent.

But on the whole this dairy is an excellent demonstration of GEA Milfos’ readiness to accommodate any level of technology their clients want.

As well as the pumps and wiring the dairy, Kelvin Witheford and his apprentice Shane Reid also rewired the old farmhouse that’s being renovated for the farm.

“Once again, I went to Kelvin because he’s local, gave me a good price and I’ve had 50 years’ experience with him, so I trusted him to do a good job,” says Roger.

One key system

Kelvin Witheford shows off his variable speed units.

The Milfos milking plant ready to go.

Kelvin has the dairy working on a ‘one key system’ so that anyone can come in, turn it on and milk. Then at the end of milking switch everything off with the key.

Russell Corfield from R Corfield Electrical & Refrigeration Ltd looked after Roger’s refrigeration needs with a chilled water unit that works on off-peak power and a vat refrigeration unit.

“The milk needs to be brought below seven degrees Celsius within four hours. We’ll be putting it in at about 12 degrees Celsius; and then the refrigeration unit on the vat will bring it down and maintain it at the required temperature,” says Russell.

And it’s not just cold water coming out of the refrigeration unit, the heat recovery pack Russell installed will produce hot water at a respectable 55 degrees Celsius.

More locals – in fact from just a couple of

kilometres down the road – brothers Kurt and Nick Johnson from Trenching & Irrigation took care of all the farm’s water and effluent reticulation.

Water works

Together with their father, the boys got the water from the bore to the tanks, then on to the dairy and beyond. They also organised the effluent disposal.

Bob Hill-Rennie had excavated a 30m by 30m by 4.5 m – about 4050m3 – effluent pond and prepared it for the Viking pond liner – and for Kurt and Nick to hook up to the dairy.

Originally the pond was to be much larger, but this was reduced when Trenching & Irrigation diverted the rainwater run-off from the dairy away from the pond – saving Roger a considerable amount of money in the process.

Originally Roger had another company lined up to install the effluent pond liner, but they kept “mucking him around” so he had a rethink.

Bob had experience with Viking and recommended them to Roger, and his timing was just right.

The South Island was in a cold snap that made it too cold to weld plastic, and jobs had to be put on hold, which meant they were able to be on Roger’s job virtually straight away.

There was certainly no mucking around with Viking – and they did it for $10,000 less than the original quote, and threw in a free barbecue as well. You can’t ask better than that.

In fact, Roger couldn’t have asked for better in any aspect of his dairy – he has exactly what he wanted, while leaving his options open for future changes.

By Graeme Dobson

Brothers Kurt and Nick Johnson from Trenching & Irrigation handled all the reticulation for the new conversion, including the dairy and effluent.

Russell Corfield, from Russell Corfield Refrigeration & Electrical Ltd, shows off his refrigeration units.

RED DOG DAIRIES

Page 28

Coast & Country

Outdated dairy leads new owners to improvise Tucked away near Mangakino, in the South Waikato, equity partners Vaughan Parker and Paul Smith are establishing themselves on 111 hectares of the best dairy land you could ask for.

Initially they intend on milking 296 cows and increasing to 400 during time.

The property had an old and badly outdated dairy on it, so they started looking around for local contractors to build a new one.

The design they chose is a 32-aside herringbone by Chapman Dairy – a name well-known and respected throughout the country.

Chapman Dairy has a number of licensed franchisees throughout NZ, who erect the dairies. In the central North Island it’s Ben Wright from Built Wright Construction.

Smooth site prep

After the planning phase, the first contractor on-site was Wayne Mankelow, from local company WR Mankelow Earthmovers, to put in the tanker track, effluent pond and prepare the ground for the dairy.

“Normally we’d do all the races as well, but a lot of these races were already here and Paul

right into electronic logging of water use now could bring them up to scratch himself,” says because Waikato Regional Council’s Variation Wayne.

Six will require stock water and cow shed water The majority of Wayne’s work is local and to be recorded separately,” says Michael. varied. He does everything from bush root raking to grading raceways, preparing dairy building sites and contouring for irrigation Cow flow pivots.

Then the stage was set for the main contracAfter Wayne finished preparing the site, tor on the job, Built Wright Construction.

Michael Grafas from Capitol Trenching & IrriBefore starting the build, Ben and his clients gation Ltd followed up with all the trenching went over the Chapman Dairy plan and fineneeded to drain the dairy and get the effluent tuned it to the Paul’s particular requirements. into its pond.

In this case they produced a nice, basic, easy He’d normally also get it out onto the padto maintain herringbone with no major extras. dock, but like the raceways, Paul is handling “The Artificial Insemination and vetting that himself. area are the only But Michael is things out of the preparing a plan ordinary because for installing a they’re set away new water system from the buildfor Paul – as a ing,” says Ben. new conversion “Basically, we they haven’t aim to maximise got any ‘grandcow flow in eveparenting’ water rything we do. rights, so making “You have to the dairy water learn to think like efficient is a a cow if you’re GEA area sales manager Austin Heffernan with priority. going to get the farmers Paul Smith and Vaughan Parker, and “We’re getting cow flow right, Ben Wright from Built Wright Construction.

see what’s going to scare them and work around it.”

All the steelwork was done by Taupo-based Matt Nash, from ARC Engineering, who regularly works closely with Ben. “We offer total engineering in the dairy, all with a focus on quality,” says Matt.

“Everything from the structural steel through to the yards, including installing our own designed round yard backing gates.”

Easy to clean

Matt and Ben have to be very particular to make the dairy easy to clean.

Quality Consultants New Zealand Ltd, the NZ regulator of dairies, inspect all dairies to make sure they’re up to scratch as far as cleanliness is concerned – so this building needed to meet strict requirements.

Meeting these standards was made easier for Ben by Modern Coatings’ Roger Farley, who applies a tough Acraflex sealing coat to the pit walls of all Ben’s dairies – ensuring they’re sealed, easy to clean and meet all regulations.

Acraflex isn’t just functional, it’s distinctive flecking looks good and brightens the whole pit area up. Roger also applied a regular paint to the front of the stand and the rooms to finish the job.

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Page 29

The earthworks, including the effluent pond, were done by WR Mankelow Earthmovers.

ARC Engineering’s Matt Nash and his crew.

The milking machinery chosen by Paul and Vaughan is a GEA Milfos system with iCR Cup Removers and a swing-out jetter system to make it easier for Paul and his staff.

GEA area sales manager Austin Heffernan says the set-up allows for future expansion.

“But for now the focus is on making this a simple one-man operation,” says Austin.

“Although it’s got a Milfos Blower vacuum system with a variable speed drive and a Milfos iNTELJET 150 – an air injector that blows water down the lines to ensure an effective clean – the plant itself is fairly simple,” says Austin.

“The plant works on a two-by-two pulsation system with one four-port pulsator running two clusters.

“It’s more efficient than the old system, where a pulsator meant for one cow was made to work for two.

“And an iNTELFLOW variable speed milk lift pump gives a better, more constant milk flow through the plate cooler for a more efficient cooling process,” says Austin.

The GEA Milfos plant – along with the in-

bail meal feed system and all the dairy’s water – was installed by the local GEA Milfos agent Daniel Gorton, who is managing director of Mainland Engineering & Dairy Systems.

Daniel says installing the milking plant is made simpler by the modular GEA Milfos design, which can be easily and efficiently adapted to any sized herringbone, saving time – it takes about 10 days to fit-out a dairy like this one – and ultimately cost to the client.

Water conservation is an important consideration and the GEA iCONVERTER aquaCHILL unit minimises ground water use in the refrigeration process.

Aqua chills

The aquaCHILL strips about 10 degrees Celsius from the milk to get it into the vat at the required temperature.

Then a Taupo Refrigeration & Air CondiMainland Engineering & Dairy Systems tioning supplied and installed DX refrigeration managing director Daniel Gorton, and GEA system keeps it cool. area sales manager Austin Heffernan.

The iCONVERTER aquaCHILL unit comes on-site as a complete unit mounted on its own “We’ve known of Laser Electrical Putaruru for skids. a long time.

It was simply put in place and wired in by “They’ve got a very good name and they were Laser Electrical Putaruru. The milk lines were really helpful in designing the dairy and the fitted by Dan and ongoing servicing is done by power—especially the size of the transformer Taupo Refrigeration & Air Conditioning. we needed because of the snap aquaCHILL.” Laser Electrical also worked out the new All the contractors on-site often work with transformer needs and fixed up the high voltage Ben, GEA Milfos and Dan, so they know their power. way around each other very well – and this “We hooked up with Taupo Refrigeration shows in the quality of the job. Although, the through Mainland and they did a really good red dog wasn’t impressed enough to wake up job for us,” says Vaughan. and join us.

By Graeme Dobson

Simple feed system

The in-dairy feed system Daniel installed has two 16 tonne silos fitted with ladder cage kits for safety and vibrators to ensure a smooth grain feed to a mill, which grinds it into meal then an auger system deposits it in bins along the front of each bail. Simple but efficient – just like the water reticulation.

“The water supply to the dairy is two 30,000 litre plastic tanks and a two-pump wash-down system, a 5.5 kw wash down pump for heavy work, coupled with a 1.1 kw services pump to give a combined power of 6.6 kw if it’s needed,” says Daniel.

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Page 30

WAIPUPUMAHANA TRUST

Coast & Country

Maori land returns to dairying with new shed Waipupumahana Trust is a short drive from Rotorua, at a small place called Horohoro.

Horohoro is situated about 15 kilometres southwest of Rotorua. Horohoro’s full name is Te horohoroinga o-nga-ringaringa-a-Kahumatamomoe – see if you can wrap your tongue around that one.

Horohoro was named after an incident where the explorer Kahumatamomoe was cleansed by a priest after he touched the dead body of an important chief.

I spoke with Iris Kirimaoa, who is the granddaughter of Kirimaoa Haira.

The farm, which back in its day was under the Ngatiwahiao tribal area, was inherited by Kirimaoa Haira as his shareholding through the tribe.

Grandchildren

Kirimaoa then passed his shareholding onto his own children, which later passed it onto their children. The grandchildren, one of

which is Iris, then formed the Waipupumahana C Trust.

Back when Kirimaoa Haira farmed the land, he used to farm sheep, beef and dairy cows.

The cows were milked in a small shed and all milked by hand, which is a far cry from the high technology and farming practices of today.

Back in Iris’ grandfather’s day, the families used to travel by horse and cart from Whakarewarewa to Tuwharetoa, and would stop off at the farm and stay overnight, soaking in the hot springs that are still on the farm today.

Once the grandchildren took over ownership of the trust and renamed it, they leased the land out for 20 years as sheep and beef unit. In recent years Murray Scott has been leasing the land.

The trust did some market research, and the timing was right in terms of dairying.

There were no dairy farmers within the family and they needed a good partner for the success of the venture.

As Murray had farmed the land so well and utilised the land to perfection, the trust decided on a sharemilking venture with him.

The decision between them to convert the farm to dairying was the natural step to take.

Murray will be milking 450 cows on this farm through the new shed. The farm consists of 177 hectares, with 150 effective hectares.

The longest distance the cows will need to walk is 20 minutes. Murray employs a farm manager plus one farm worker, and will also employ a calf-rearer.

Murray also sharemilks on four other units, between Horohoro and Tirau.

Leasing the Waipupumahana land for the last two years as a run-off for his other farms, Murray could see the potential for a profitable dairy farm.

Discussions with the trust saw this come to fruition.

A place for everything

Dane Lowe from Lowe Builders was on-site to run New Farm Dairies through their part in this project.

Once sitework was complete, the construction began in earnest, says Dane.

“There were a few hold-ups with consents not coming through on time, but apart from that everything

was fairly straightforward.”

The shed itself is a standard 44-bail herringbone design, with a row of rooms down the side of the drenching rails.

The rooms are the usual milk room, office, toilet and supplies room – all covered in poly panel for easy cleaning.

This shed has a place for everything, while being minimal in size. The outside of the supply room is accessible from the tanker track area, via a roller door, as well as from the pit side.

The pit walls have a nuplex coating for protection and ease of cleaning. The nuplex coating was applied by Lowe Builders in five coatings.

Two were a white coating with fleck, followed by three coatings of lacquer. The shed itself is very neat and tidy, light and airy.

There is an added AI race down the other side of the drenching rails. This has drop sides for easy access to the cows. All of this is accessible from a large circular yard.

The auto drafting system was installed by Tanner Industries Ltd. “We do the lot,” says Lloyd Tanner.

The exit to the bails is done through the Ezi-Flo pit gates manufactured by Waikato Dairy Builders.

Waipupumahana Trust L to R: Trust sharemilker Murray Scott, Tanner Industries Ltd’s Lloyd Tanner and Lowe Builder’s Dane Lowe.

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Page 31

Horohoro herringbone makes milking easy The effluent wedges built

by Lowe Builders.

Looking at the front of the shed.

The feed pad area constructed by Lowe Builder, with the Thomson Concrete feed bins.

The feed pad was also constructed

by Lowe Builders. This is a large concrete area to the side of the shed and yard area, filled with rows of feed troughs manufactured by Thomson Concrete in Otorohanga.

The troughs are in three rows of continuous bins with both ends enclosed.

Thomson Concrete supply feed troughs either as single troughs or a choice of one end closed or both – the choice is yours.

Multiple options

With such a magnificent effluent system in place, it’s sure to keep everyone happy.

Lowe Builders has constructed a splendid effluent system. Not only is it pleasing to the eye, it is also a very simple but effective set-up.

It consists of three large wedges, or bunkers, with a weeping wall in between each bunker.

The effluent and water run-off from the yard runs into a large channel at the end of the pit.

The run-off then flows through a large pipe, which can be diverted into either of the three wedges, by the quick flick of a valve.

The reason for having three wedges is if one cannot be emptied, due to time restraints during busy times of the year, there’s the option to use the other wedges.

Once the run-off enters the wedge, the sludge settles on the bottom of the wedge, and the remaining water is filtered through the weeping wall on its way to the lined effluent pond.

The sludge is then removed with a bucket on a front-end loader and disposed of as time allows.

Right angle stirring

With any pond, there are advantages in having the solids suspended by agitation.

This is particularly important for preparation of discharge to irrigation and minimising potential blockage in the irrigators’ nozzles.

Also good maintenance of the liquid in a pond will minimise the need to have solids built up and removed at a later date.

The Yardmaster right angle stirrer is designed for just this job and particularly for larger ponds. The right angle stirring creates a whirlpool effect, so all areas of the pond are reached by the liquids’ movement.

The Yardmaster right angle stirrer is located on a Yardmaster 6 drum floating frame.

The frame, with attached control arm, is designed to give a stable platform for the equipment to operate from.

Also on this frame is a 30hp Yardmaster effluent pump, which supplies the required

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pressured delivery to feed the 20 easy skid irrigators.

The Yardmaster pump is designed to handle any solids that may pass through.

And with the bearings being above the liquid, the pump provides a trouble-free operation – even to the point where it can run dry.

With Yardmaster’s known reputation for reliability and getting the job done, it provides the best solution to the delivery of the effluent system to the pastures.

Trusty milking set-up

The Team at Tanner Industries Ltd from Putaruru installed the 44-bail herringbone DeLaval milking system and shed water system.

The herringbone has swing arms for cluster/ cow alignment.

Page 32

WAIPUPUMAHANA TRUST

Coast & Country

Grandchildren go dairying on trust land Waipupumahana Trust

The new farm manager’s house, built by JLN Builders.

Milk is pumped with a DeLaval 2.2kw Centrifugal milk pump on a Dairy Flo milk pump controller.

These pumps keep the milk moving as slow and constant as possible to allow the heat exchanger to remove as much heat out of the milk before it enters the vat.

The vacuum pump is a DeLaval LVP 4500 lobe pump, which provides a constant volume of air on every rotation, is reliable for long operating times.

The vacuum pump controller dramatically reduces noise levels and cuts energy costs by up to 70 per cent.

No interference

Some variable speed drives can interfere with electrical equipment, such as herd management and cow identification systems.

DeLaval’s variable speed drive doesn’t interfere with any other componentry in the shed.

The new implement/calf shed built by JLN Builders.

The DeLaval water chiller heater MD1022 is a cost-effective, pre-cooling solution that rapidly reduces the temperature of milk before it enters the milk vat.

This is achieved by cooling a water, foodgrade glycol mix that’s then circulated through the secondary side of the double-bank plate heat exchanger to chill the milk.

With nominal flow rates of 2200-2500 litres per hour, milk temperature is rapidly reduced by eight-10 degrees Celsius.

The heat recovery unit generates 50 degrees Celsius water with a flow rate of four-six litres per minute plumbed back to the hot water cylinder.

Murray also uses DeLaval’s range of dairy hygiene products through the C200 automatic wash unit for a thoroughly clean and efficient set-up.

A DSG3 sort gate – three-way drafting system – has been installed. It saves labour and

Tru-Test’s DTS Milk Vats.

allows for easy separation of cows with high accuracy levels.

Lance McFarlane from Tru Test’s DTS sold the trust a new 14,000 litre milk silo with a polar wrap fitted.

The refrigeration unit supplied is a new Patton Pak PZB1300DU. This is a 13hp waterproof-type unit running R404 gas that sits outside without the need for a cover.

It has vertical fans, which expel the hot air upwards and away from the unit – and this prevents the unit recycling the hot air it produces.

The full electrical work for the shed, housing and barns were all done by TL Cole Electrical from Tirau. The electrical wiring set-up for the shed is your standard install to run a shed of this size.

Housing for all

The trust has ensured it will have a happy content farm manager by having a very smart

four-bedroom brick home built by JLN Builders Ltd from Tirau.

The house has a floor area of 214m2, and has a double garage.

JLN Builders Ltd builds Competitive Homes. Competitive Homes offers a wide range of homes at competitive prices, hence the name.

John Allen worked with the trust to help with the complete building package from design, right down to the last little finishing touch.

The calf-rearing barn and workshop is a Bunnings kitset package, also built by JLN Builders Ltd. At the time of New Farm Dairies’ visit there was still some work needed to complete this project, such as fencing and tanker track.

But all was expected to be completed well prior to calving.

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Page 33

PENGXIN NZ LTD

Page 34

Coast & Country

The new dairy parlour, constructed

by Built-Wright Construction.

Overseas owners make time-saving dairy In December 2012 Pengxin NZ Ltd purchased 16 Crafar farms, which consists of about 8000 hectares – and between them about 16,000 cows.

By Lois Natta

Thirteen of the farms purchased are dairy farms, with the remaining three drystock units.

With Crafar farms going into receivership, this opened up the potential of Chinese investment into New Zealand farming.

There were an enormous amount of conditions included in the sale to Pengxin NZ Ltd, and these conditions are progressively being met.

Some of the conditions of sale were building new dairy sheds, upgrading effluent ponds, renovating farm housing and fencing, to name a few.

This is a joint venture between Landcorp Farming and Pengxin, which has also bought into Synlait.

Landcorp oversees and manage the Pengxin group of farms – and there’s a huge focus on animal health.

One of the Pengxin farms is a Reporoa dairy farm called Pineview Farm. It’s nestled in the back of Reporoa amongst lots of flat land surrounded by distant hills and pines.

The day New Farm Dairies visited was rather bleak and cold and the distant hills were shrouded in ominous-looking clouds.

Arriving at the shed, after a lengthy drive up the tanker track, a neat and tidy appearance of the property impressed.

The tanker track was pristine, with loads of room and was well-compacted to cope with the wear and tear of day-to-day usage.

Landcorp’s farm project manager Mike Karl oversees a number of Pengxin farms – including Pineview – as well as owning his own dairy farm in Ngatea.

The farm milks 1100 cows, which were originally on the Crafar farm.

The cows are grazed on 320 hectares and milked in three herds.

Target achieved

JRK Drainage & Roading Contractors director Jim Brookes was commissioned to do all the site preparation, tanker One of the JRK Drainage & Roading track and the main raceContractors trucks. way work.

Once the site was marked out Jim was given the plans with the requirements of achieving a plus or minus of 20mm, or thereabouts, with his diggers and bulldozers.

Topsoil was stripped off the tanker track and building site, and dumped to a stockpile.

Pumice was then loaded and carted onto site using three six-wheeler trucks. This was then compacted into layers of 150mm with a CS563 12 tonne roller.

The main race was levelled, contoured and layered with pumice.

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Based in Te Kuiti, Jim says the travel doesn’t concern him in the least as his business also does a lot of forestry roading – so travel as far afield as Port Waikato, Wanganui and the West Coast is fine, as his boys love getting away.

Jim has been in the earthworks business for 16 years and prior to that managed a drystock operation.

“I do a lot of work for Pengxin,” says Jim. From left: Built-Wright Construction’s Ben Wright, Mainland Engineering’s Daniel Gorton, Landcorp’s farm project manager Mike Karl and Mitch, from Mainland Engineering.

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Page 35

tics tanks.

The feed silos next to the Promax Plas

The Tru-Test’s DTS milk vats.

A cow going through the Protrack drafting

race.

Some of the cows on Pengxin’s Pineview Farm.

Pengxin’s new Pineview dairy performs “They also have a couple of dairy farms near Bennydale. Plus, I’m doing a lot of cow race maintenance work on their Tararua block on the Napier-Taupo highway.”

Light, airy and low care

Building began once the site work was complete. Ben Wright from Built-Wright Construction built a Chapman Dairy designed shed.

Ben is one of Don Chapman’s select team of self-employed builders throughout New Zealand and covers the Central Plateau and South Waikato regions.

“This is a standard and basic Chapman Dairy design,” says Ben. “It’s a very roomy 60-bail building, with three outer rooms consisting of a pump room, store room and a very necessary toilet.

“Inside the shed is very roomy, light and

airy. One corner of the shed has been set up as a smoko room and office, with yet another corner being allocated to benches, and another for the milk wash area.”

The shed itself is set up with lots of windows, which open up for good airflow in summer, and during winter let in lots of light.

The walls are made of poly panel, which has the benefit of being super easy to clean and also very low maintenance.

The main shed area is 400 square metres – and everything has been robustly built to last the distance.

The block-work is coated with an acraflex coating, which was applied by Roger Morley from Modern Coatings.

Ben contracts Roger to do the acraflex work for all of his sheds.

Another Chapman Dairy design is the clearlite vented apex roof. It has a strip of clearlite

which is vented to assist with airflow and also allows in more valuable light.

There is a raised vet area with a fold-down platform, which is being well-used in the new shed.

Outside the shed is a covered lean-to area, which is used for Artificial Insemination.

The reason this is outside the main milking parlour is AI can be done while cows are still being milked in the shed. It took Ben and his three staff members 15 weeks, from start to finish.

Shed fit-out

Mainland Engineering from Taupo had a big part to play in this project too.

Not only did they do the install of the GEA Milfos plant and machinery, but they also carried out all of the yard work, erected the existing feed silos, and laid all of the water

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reticulation, as well as erecting portals in the shed.

The shed is an iFLOW 60-bail rotary double iBEAM concrete platform with hydraulic drive units and iPUD leg spreaders.

The iFLOW is built onto a raised plinth, which means the milking machine is mounted under the platform.

This provides physical protection as well as making maintenance of the milking machine easy.

The GEA Milfos milking plant is fitted with iPULSE pulsators. iPULSE is a new generation of pulsator, engineered for long life even in the harshest of working conditions.

A single pulsator is designed to handle either one or two cluster assemblies. iPULSE is sealed from water and moisture contamination, and the electrics are housed away from the pulsator chamber.

Page 36

PENGXIN NZ LTD

Animal health paramount at new Reporoa parlour The system is also fitted with an iROTAVAC vacuum pump with iNTELVAC variable speed controller. The iROTAVAC features a unique twin exhaust system.

The primary muffler has insulating material and internal baffles to diffuse the soundwaves coming from the pump, which effectively cancels out any noise generated.

Mainland Engineering also installed an AP automated meal feed system, which the cows just love.

This is a basic shed fit-out, but it’s been futureproofed to allow for Milfos iCR intelligent cluster removers and cow restrains to be fitted in future.

All water pumps in dairy shed are Lowara. The main shed wash down pump is 7.5kw pump with a Hydrovar VSD. Two vat wash pumps were installed, along with a primary cooler pump, as well as a secondary cooler pump.

The yard rails are all 1350cm high and the yard is a 15metre-round yard with a holding capacity of 400 square metres.

Chilled water system

Taupo Refrigeration and Air Conditioning installed a chilled water system to chill milk to below 10 degrees Celsius with heat recovery for plant and vat cleaning as a by-product. They also installed a separate vat chiller unit to run Tru-Test’s DTS vats.

“Both machines have variable speed drive condenser fans for precise head pressure control,” says TRAC’s Lawry Bidgood.

“This assists greatly in delivering high levels of refrigeration performance and power-saving in varying temperatures and product loads.”

The dairy itself is a basic shed, with not a lot of bells and whistles, but what it does have is a Protrack

drafting unit in the exit race.

The Protrack drafter is very much an entry level solution to farm automation. It’s a stand-alone drafting system that can be operated even if the user has a low level of computer literacy.

The Protrack drafting unit can be used in all types of sheds, and is driven by an indairy touch screen that’s very easy to use.

The cows electronic IDs are preloaded into the touch screen; then the cow is identified at the drafting gate for sorting.

Remote controls are also supplied with the drafting gates and these can effectively be used within a 50m radius of the drafting gate.

The cows being milked on the GEA Milfos platform. new

The new dairy’s emergency assembly point.

Engineered to last

There have been three 25,000 litre Promax water tanks installed at the dairy which feature tough, one-piece corrugated construction.

These ultra-strong water tanks are engineered to last. This also means no maintenance is required. They also come with a 20-year guarantee, which has to make them an appealing choice.

Milking for the first season of the Pengxin ownership was done in the old shed, taking eight hours to milk.

Now, with the new shed up and operating for two months, it takes a mere 2.5 hours to milk.

Now that’s a time-saver.

By Lois Natta

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LIMESTONE DOWNS

Page 38

Limestone Downs on the West Coast, 15km south of Port Waikato, has played a prominent part in New Zealand’s agriculture history – and still does.

By Helen Wilson

The land was originally bought in 1926 by CBE recipient Charles Alma Baker, who was born in New Zealand and went to Malaya in 1890 as a surveyor.

While there he invested in tin mining and the rubber industry to great advantage.

He used his financial resources to develop the 3219 hectare northern Waikato farm into a sheep and beef unit, using the most modern methods available such as applying fertiliser by aeroplane.

Charles died in 1941 and the farm was left in a trust, to be administered by his English trustees.

In 1981 the trustees appointed a New Zealand committee, which has taken over the running of the farm. The committee works in association with Massey University with major research and development programmes.

The profit from the farm goes towards a range of charities, mainly agriculture-based, such as scholarships for young farmers to further their education.

Alf Harwood came to work at Limestone

EASK Established 1958

Downs in 1986 as second in charge of the sheep and beef farm and is now operations manager, overseeing the whole operation including the new dairy unit.

The farm is mainly hill country, some of which goes down to the coastline, creating some challenges.

There is about 350ha of flat to easy rolling land which had been “humped and hollowed” for drainage. “We decided the best return for investment would be turning the flats into a dairy farm,” says Alf. “Along with our farm advisory officer, Kevin Lowe, we did some research and budgets; and for every kilogram of dry matter the flats produced, dairying would be the most profitable.

“It would also futureproof the trust, which is set up to continue in perpetuity,” says Alf.

Good reputation

After looking at several rotary dairy sheds, they settled on Chapman Dairy from Morrinsville.

“We decided that Don’s dairy sheds were good value, he’s been building them for over 30 years and all the farmers we talked to were more than happy with the result,” says Alf. The consent from Waikato Regional Council to start the earthworks came through in January 2013 and the new 60-bail rotary dairy shed was started and completed on July 23.

All the bulls were sold off the farm and

NGINEERING

730 dairy cows were brought in. Because of the severe 2013 summer drought there were plenty of cows available; and the intention is to increase the herd to 850 cows in 2014.

“It was a tight deadline but we managed it,” says Alf. As some of the cows calved before the completion date, they were milked on a neighbouring farm.

Aaron Frazer is the first Limestone Downs dairy farm manager and is assisted by two full-time staff.

“I arrived here when the dairy shed was being built, so I was able to help with the project management,” says Aaron. He’s been a dairy farmer on and off for 13 years and is enjoying the challenges at Limestone Downs.

The dairy shed is located quite close to the West Coast and salt spray can cause rust problems. Although the rotary dairy was a standard Chapman design, allowances had to be made for this problem.

“The design was modified a little to fit in with the landscape, a milking pit was put in as we had to create an elevated area for visitors

Coast & Country

to watch the milking and keep them out of the way,” says Don Chapman.

“Because of the salt spray the portals are made from laminated timber and the fittings are made from stainless steel to prevent rusting. I had built a similar one near Patetonga, so it stood me in good stead for this one.”

The elevated site was chosen for effluent gravity so there is no need for an effluent pump, but Don admits it was a tight site and a tight timeframe.

“The dairy was positioned so we could build a large feed pad beside it and allow easy cow flow from one to the other in summer or winter,” says Don.

Clean and fast milking

Rural Supplies Pukekohe is the Waikato Milking Systems agent for north Waikato and installed the high-end milking system.

Limestone Downs’ dairy farm manager Aaron Frazer in his preferred farm transport.

LIMESTONE DOWNS

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Future-proofed system

The well-used implement shed built by Aztech Buildings.

The WMS Orbit platform.

The dairy shed and yard.

)RU D PRUH HIâ&#x20AC;Ť Ű&#x2039;â&#x20AC;ŹFLHQW IDUP GDLU\ Li^\bZeblbg` bg _Zkf ]Zbkr ]^lb`g Zg] \hglmkn\mbhg With a lifetime of experience designing and building farm dairies, weâ&#x20AC;&#x2122;re well equipped to create a design that suits your exact needs, no matter what.

Our customised design process provides a choice of options in shed styles, yard layout, plant room design and pipe work configuration.

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Page 39

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Helping turn Limestone Downsâ&#x20AC;&#x2122; vision into reality! waikatomilking.co.nz | 100% NZ Owned & Operated

It is a 60-bail Orbit rotary with a quality milking machine and dairy technology, all designed and manufactured by Waikato Milking Systems. â&#x20AC;&#x153;This future-proofed system can handle up to 1500 cows per milking,â&#x20AC;? says Rural Supplies Pukekohe owner Robert Morrow.

The Orbit concrete rotary platform provides a clean and fast milking environment and excellent cow ďŹ&#x201A;ow. Its 2.7m deck ensures optimal protection of the equipment. The unique SmartFit mounting system enables the milking machine to slide perfectly into place under the platform. Limestone Downs chose a range of Smart products from WMS for additional beneďŹ ts through technology.

SmartECRs make milking faster and save labour, while the SmartSPRAY automatic in-bail teat spray system provides optimal teat coverage.

The SmartWASH system provides an excellent clean, and allowance has been made to add the automatic mastitis detection system SmartD-TECT in the future. â&#x20AC;&#x153;All Waikato Milking Systems are speciďŹ cally designed for ease of use and integration,â&#x20AC;? says Robert.

Limestone Downs also chose to add a SmartDRIVE vacuum pump controller, which provides power savings of up to up to 47 per cent. The vacuum pump speed is adjusted according to airďŹ&#x201A;ow demand, using digital sensors.

Robert has been installing milking machines in dairy sheds for more than 20 years. He has four permanent staff including himself, Chris Perry, Kevin Harris and Peter Short. They provide a 24/7 service.

Dairy farm manager Aaron is more than happy with the service; â&#x20AC;&#x153;always there when neededâ&#x20AC;?.

Refrigerated Panels, supplied by Insulation Panel and Door, were used for the walls in the dairy shed.

Bruce Cameron of Specialised Coatings provides an epoxy resin coating on walls which is aesthetic, easy to keep clean and complies with the dairy industryâ&#x20AC;&#x2122;s stringent hygiene standards. There are a number of colour combinations to choose from.

Covering the essentials

Complementing the dairy shed is an Aztech Buildingâ&#x20AC;&#x2122;s ďŹ ve-bay implement shed which houses tractors, quad bikes and various other essential farm equipment. At one end it has a lock up room for hazardous materials.

Aztech Buildings offer a range of rural buildings and cow and goat dairy housing solutions. The buildings can have timber pole or steel column options that are suitable for higher roof structures. Aztechâ&#x20AC;&#x2122;s dairy housing solutions have various beneďŹ ts to increase production and proďŹ tability including reduction in total efďŹ&#x201A;uent volume, improved animal welfare and increased pasture management. Aztechâ&#x20AC;&#x2122;s rooďŹ ng systems can have partial clearlite panels and ventilation options to manage light and heat inďŹ&#x201A;ow from the sun.

Clear-span solutions, with the ďŹ&#x201A;exibility for internal support options, give greater space availability and Aztechâ&#x20AC;&#x2122;s zero-birdperch roof systems ensure bird droppings within the structure are kept to a minimum. Aztech Buildings can build over any surface or efďŹ&#x201A;uent system and is compatible with comprehensive managed efďŹ&#x201A;uent and stormwater systems.

Tru-Tests Dairy Technology Servicesâ&#x20AC;&#x2122; Waikato area manager Dave Gray says the refrigeration system they installed at Limestone Downs is designed around the number of cows and the new requirements coming into force in 2016. â&#x20AC;&#x153;Itâ&#x20AC;&#x2122;s a very costeffective and energy-efďŹ cient system.â&#x20AC;?

LIMESTONE DOWNS

Page 40

Trusting good tradies The milk is first cooled with an energy efficient doublebanked plate cooler using chilled water to below 10 degrees Celsius, then five degrees Celsius, and finally to 4.5 degrees Celsius which is below the industry standard.

Dave has 20 years’ experience in the refrigeration industry and says there is lots of enquiry for refrigeration especially with Fonterra tightening up on milk temperature regulations.

Collett Electrical Limited has been providing rural, commercial and domestic services to the Franklin area for more than 30 years. They were responsible for the electrical work at Limestone Downs’ new rotary dairy. They provide a full back-up service to all customers.

Welding for the backing gate, yard and feed pad rails and gates was done by Leask Engineering, based at Tatuanui near Morrinsville. They’ve been building dairy sheds for 50 years and rely on the builder to have the layout organised so they can come along and install the rails.

“We can do any modifications on-site when needed.

This dairy shed has rails at standard height and strength.

The corners have been rounded off on the pressure side for cow comfort, and to stop any injuries. Every dairy shed is individual and we fit in with the farmer’s requirements,” says Leask Engineering’s design and construction manager Rom Stellingwerf.

They are proficient in constructing herringbone dairy sheds as well as rotaries, and Rom says “there is still a lot of inquiry out there”.

Coast & Country

Limestone Downs’ dairy farm manager Aaron Frazer and operations manager Alf Harwood.

Tru Test’s Dairy Technology Services’ Waikato area manager Dave Gray.

Drafting during milking

The Protrack system by LIC is a stand-alone automated drafting unit which is easy to use by any staff member and they don’t have to be computer literate. The Protrack Drafter allows drafting to take place during milking.

A single touch screen close to the milker controls the system. Animal EIDs are preloaded into the touch screen and the cow is identified at the drafting gate and drafted into the appropriate pen where she can be attended to after milking. The Protrack Drafter can be installed in herringbone or rotary dairy sheds, with equal efficiency.

The dairy construction team: Limestone Downs’ operations manager Alf Harwood, dairy farm manager Aaron Frazer, builder Don Chapman, Tru-Test’s Dairy Technology Services’ Waikato area manager Dave Gray, Waikato Milking Systems’ Josh Norquay, Rural Supplies Pukekohe owner Robert Morrow, Leask Engineering’s design and construction manager Rom Stellingwerf, and Don Chapman Builders’ Geoff Booth.

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LIMESTONE DOWNS

Page 41

The feed pad and a great view of the hills.

New dairy fits vision Dean and Natalie Smith own D&N Smith Contracting, based at Glen Murray, and have just finished preparing house sites for a 100-lot subdivision. At Limestone Downs they cut and levelled the area to build the dairy shed, feed pad and silage bunker.

“It took about a month, we had good weather and used two motor scrapers, a bulldozer, dump truck and three excavators,” says Dean. D&N Smith Contracting is equally experienced in rural or domestic earthworks requirements.

While the dairy’s site was being prepared, the new farm races were being formed by Pearce Earthmovers from Waiuku. Graham Pearce has been in the business since 1965 and now his son and two other operators work for him.

“I had to use ‘morookas’ which is like a tractor on rubber tracks, as some of the ground where the races went was peat and a bit soft for a regular tractor,” says Graham.

“We also prepared the new house site and dug all the drains.”

He had three diggers working on

walls were installed for the job, and once solids separation prior to the raceways were flowing in to the pond. formed he carted The effluent is spread to in the metal pasture with a low rate and spread that K Line system applytoo. “These are ing only 3mm/hr to raceways to last a the sensitive soils. The lifetime.” system also recycles green Limestone water on the feed pad via Downs engaged flood wash system. There AgFirst Engineeris only one pump that ing to design and build their dairy Leask Engineering’s design operates the complete effluent system. and construction manager system and everything is gravity all the way The effluent Rom Stellingwerf. to the pond resulting system designed was governed by a few key factors such in a very simple and easy to manage system. AgFirst Engineering was also as a high water table and soils with involved in the design and build of the impeded drainage. A 20,000m3 or 20 farm water supply and land drainage million litre pond, which has a worksystems. Limestone Downs welcomes ing volume of about 16,000m3, was visitors to the farm and holds an open constructed for effluent storage. The day at the end of February each year. bottom of the pond is above ground They’ve adapted the farm to make the water level. Because an organic peat most of the current farming climate layer was found down deep, the soil under the pond has a drainage system, and the new dairy complex sits well within the trust’s vision, which is which also helps to vent any methane encouraging young people to make a from under the liner.

Two solids drying beds with weeping career of farming.

By Helen Wilson

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Limestone Downs’ dairy farm manager Aaron Frazer, Waikato Milking Systems’ Josh Norquay, Limestone Downs’ operations manager Alf Harwood and Rural Supplies Pukekohe owner Robert Morrow share a joke.

The effluent pond.

LIMESTONE DOWNS

Page 42

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Page 44

Coast & Country

Mangatawhiri dairy makes family happy Brent Welch’s new dairy stands proud near Mangatawhiri – ready for the 2014/2015 season.

By Merle Foster

About 20 years ago Harry Welch bought his first block of land – about 100 acres – at Mangatawhiri Valley near State Highway 2 – and his family’s been working there ever since.

But he hasn’t always been dairying and neither has son Brent Welch.

During the years Harry’s acquired quite a few blocks of land in the area, and when he and his brother parted ways about eight years ago he needed some help.

So him and wife Gwenda asked their four children Julie, Brent, Malvin and Andrea to join the business. They all agreed, bringing with them different areas of expertise.

“I gave them all the opportunity to come back to support the business,” says Harry. “Luckily for me, they did.”

Brent, a builder for 13 years before coming to the farm, started milking about five years ago with 320 cows – so the new dairy’s ‘his baby’.

Last season he milked 750 cows on 900 acres in an old 16-aside double-up herringbone.

“We start milking 4.30am, and with rotating

staff finish about 11am. The next milking starts 1pm and we finish 6pm – that’s why people say we’re mad.”

With 1000 acres this season, Brent will milk 1200 cows in his new shed.

“I’ve set this up as a one-man operation because there are times when you haven’t got enough staff – so you’ve got to have a system to get those cows milked and keep the farm ticking over.”

Four staff – including Brent – run the dairy operation. Harry wanted to build on the hill-top overlooking the farm but earthworks prevented this until three years ago Environment Waikato dropped and levelled the site by six metres by in exchange for the clay. Construction began mid-2013.

Nice-looking sheds

Brent got Reporoa Engineering to build the dairy, as he liked the way their sheds look. “We wanted a nice-looking shed – they build nicelooking sheds,” says Brent.

“Dad looked at some, we looked at a few, but Reporoa’s just stood up above rest.”

Reporoa Engineering designed and built the

shed, feed pad, Herdflow Crowd Gate and built the weeping wall.

“We pride ourselves on our sheds’ milker pits and concrete tilt panel walls – they’re up to 1200mm high, and a coating makes them easy to clean and good protection,” says director John Perrin.

The milker pit sees people walk round-platform at cow level and everything is contained – crap doesn’t splash up walls.

The wide cow entry/exit helps cows onto platform, as John says Reporoa’s design optimises cow flow “which is the whole crux of a good shed”.

Extra cover protects everyone from weather, skylights lighten the building – and John was happy to install Brent’s requested male and female toilets and showers, smoko room and office.

Reporoa’s Herdflow Crowd Gate is optimum for cow safety. It’s breach sensor sees it back off when hitting cows. The gate pauses half-way down and a sensor beam stops crushing.

The gate’s fully-automated wash system

lowers the boom to concrete, turns on water and slowly washes the yard; then reverses, ready for the next herd. “At end of milking, no matter where the gate is, you just hit the wash button and go for breakfast.”

Reporoa’s 600-cow feed pad lets everyone round all troughs and the flood wash cleans it.

With Reporoa having the contract, the Technipharm Dungbuster came with the design.

Many new dairies being built have a Dungbuster auto yard washing system for the many benefits it offers over and above manual washing and provides a good step forward to sustainable use of resources.

Technipharm group CEO Harmen Heesen says effluent management and sustainability starts with less water use in dairies.

“Every drop of water pumped into a dairy and mixed with dirt, dung and waste becomes effluent. Water is precious; use it wisely.”

By installing a Dungbuster there’s a significant reduced water use, less pumping in, less effluent generated and less effluent to manage, says Harmen. “There’s a consequential saving in power-use.”

WELCH EGG CO LTD

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Page 45

The optimum one-man operation

Reporoa Engineering director John Perrin with the Herdflow Crowd Gate in action.

Farmers with Dungbusters report water use is reduced by up to 40 per cent. A 1000m2 yard takes about 2500-3000 litres water – a small fraction of old-fashioned hand-washing.

Additionally, labour savings up to four weeks per year for most farms means a saving or reallocation of at least $3000-$4000 of time – a significant productivity gain.

Dairy sustainability and production growth is all about making natural resources go further, says Harmen.

Combined effort

McLarens Rural Services installed the milking plant, drafting system, teat-sprayer, chilling system and waterworks.

This included the washdown and vat-wash systems, cooler pump and lines, says owner Tony McLaren.

The installation was a combined effort between McLarens Rural Services in Morrinsville, and McLarens Milk and Water in Huntly.

“McLarens Milk and Water will handle ongoing servicing of the Welch’s shed.”

McLarens ensured everything was set up right and as easy as possible to use.

They did SS welding, plumbed water lines under and above ground, fitted milking equipment, set up and connected water pumps, pre-piping work on the Milfos chilling system, and wired cup removers and drafting system.

Tony says the plant is standard, but the water component is larger than normal, for the feed pad.

McLarens Rural operates from Morrinsville covering 50km in each direction. McLarens Milk and Water operate from Huntly. “We’re reliable, go the extra mile and our installation and service technicians are available seven days a week.”

Brent was happy with their work. “They got in and got the job done.”

Queenstown Roofing is Reporoa Engineering’s main roofers on their dairy builds – and four of their guys travelled north to cover Brent’s dairy.

Brad Rule, one of three Queenstown Roofing directors, says they’ve began roofing

for Reporoa eight years.

“We’re based in Frankston but roof Reporoa sheds from Auckland to Bluff,” says Brad.

The guys used five-rib Coloursteel – a pre-painted NZ steel roofing product – and interspersed it with Clearlite sheetings, to cover 30 metres by 25 metres.

“It lights the dairy up and gives warmth during winter.”

The finished result is a light, airy dairy with a solid roof which can stand up to all weather –it even covers The Wrangler so vet-care can be done in comfort during wet weather too.

“Roofing dairies is percentage of our work – we do dairy roofs and dairy wintering sheds,” says Brad.

Brent says the roof provides sun to the dairy’s working spaces.

“If you make the place look nice and feel nice to work in, people are going to respect it.”

Collett Electrical wired the shed because Brent says they’ve been the farm’s electricians for years. “They’ve always done all our projects.”

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Page 46

WELCH EGG CO LTD

Brent Welch’s new dairy is light, airy and as comfortable as possible for cows and staff.

Brent’s ‘baby’ sits beautifully on hilltop Brent says the new shed was no problem for Collett.

“They know our farm and how it works – and they’ve seen the monster grow and can see where we’re heading.”

One-man operation

No more leg-roping cows to look at hooves and health issues, with The Wrangler in the new shed.

The dairy has a GEA Milfos 60-bail rotary platform and plant.

GEA North Waikato/Northland area sales manager Paul Convery says individual teat sprayers see each cows sprayed as soon as they’re milked.

Restraints drop if a cow is still milking, enabling a secondround, and automatically lower if cups are kicked off.

The cups’ spring-held string hold them above ground and travel safely under the bridge. “If a cow backs out there’s no cups in the way, and there’s an emergency button for the bridge.”

A new feature is housing electrical components under-platform, away from water and residue. You can also wash the plant with the platform in any position. iNTELAB helps Brent identify each cow’s milk yield, protein, fat lactose and conductivity.

“High conductivity is sign of mastitis – all this information goes straight to Brent’s computer.”

Brent has Milfos iCORE – but probably won’t realise until he needs to use it.

“Anything you add to a shed goes to iCORE and a farmer can adjust pulsation, teat spray and cup remover settings from his computer. It’s a milking point controller for each bail, and GEA sees it live on-screen from head office.”

GEA provides high technology, easy-to-use equipment for a one-man operation – no matter how big – meeting Brent’s brief.

“Their gear looks nice in the shed – and I like the idea of washing the manure away from the cows and where you’re working,” says Brent.

Mats for cow health

From inside the platform, this shot shows the amazing roof built by Queenstown Roofing, and designed by Reporoa Engineering to create a light, airy dairy.

Coast & Country

Reporoa Engineering advised Brent to install rubber matting in the rotary’s cow entry and exit areas.

Manufactured by Numat Industries, the mats are designed to feel like walking on natural pasture, allowing cows to feel comfortable going onto-platform and turning to exit,

which limits unpredictable cow behaviour and improves milk production.

Numat Group director Jacob Judd says AgriMat’s extra thick rubber matting improves the health and wellbeing of cows, “where research shows they prefer to walk and lie on rubber surfaces over against concrete, which is more dangerous, louder and colder in the winter”.

“Designed as a safe and comfortable surface to increase milk production, our rubber mats specifically provide a more hygienic environment where cows have reduced lameness, fatigue, hoof wear, injuries and stress.”

With long-life structural integrity and unrivalled strength, Numat rubber matting keeps its shape and provides a safe and comfortable surface for your cows for years.

“We fully guarantee the quality of AgriMat for up to 10 years, giving you peace of mind from your investment,” says Jacob.

Brent says the mat ensures cows aren’t slip-sliding their way into the bails and causing harm to themselves.

“Cows are number one – if you look after the cows they will look after you – that’s how I look at it,” says Brent.

“If you make it nice for them, they’re going to enjoy coming into the shed.”

Brent is now looking at installing some Numat matting around the feed pad.

No leg-roping cows

Until now Brent’s been leg-roping cows to look at hooves – but this is about to change.

With a Race Wrangler he’ll be able to safely and quickly treat cows.

“It has a headbail gate, belly winch with two belly girths, front foot winches with a double-rope system, a rear leg support bar and winch, and removable side bars,” says creator Wilco Klein Ovink.

“The cow is well-restrained so can’t hurt herself or operator. Hooves can be winched up and held, giving the operator good view and access.”

Brent says you’ve got look after cows hooves these days “so this an easy way of doing it”.

Roger Farley’s team from Modern Coatings Ltd painted the shed’s interior with the fleck coating Acraflex product from Specialised Coatings.

WELCH EGG CO LTD

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Page 47

Welch’s family pride shines in new parlour The interior paint-job gives the shed easy-to-clean and durable surfaces that can handle the twice-daily cleaning with harsh products. On the exterior Roger used a natural cream with a grey trim.

Brent and Harry love the building’s clean, smart look – inside and out.

“There’s lots of cowsheds out there but we wanted to make it an enjoyable place to work.

“The paint job just lifts the whole shed up.”

Complete effluent answer

AgFirst Engineering designed the dairy’s complete effluent and irrigation system.

AgFirst Engineering’s Waikato director Davieth Verheij says the farm posed a number of complexities to the system’s design.

Clay soils with impeded drainage on flat and sloping landscapes are ‘high risk’ for effluent application. And a large-surface cow yard, with rainfall catchment, would produce high volumes of effluent.

“This means the pond had to be very large to store effluent until soil conditions allow to irrigate,” says Davieth.

Design considerations were to minimise washdown water-use, remove solids from effluent, and irrigate to pasture at high volumes and low rates – maximising irrigation days and volume.

“It’s essential this was achieved with a system that’s as simple and failsafe as possible,” says Davieth.

The solution is a twin sludge-bed system with weeping walls for solids separation; the 16,000m3 lined, deferred effluent irrigation pond; a green water recycling system on yard and feed pad via flood wash; and a combination of a low-rate travelling irrigator and K line systems on-farm.

Davieth says the weeping wall – with each bed 58m by eight metres – is the largest known in New Zealand.

“It was constructed by Reporoa Engineering from pre-cast concrete with stainless steel weeping walls. Its total solids storage volume is 1400m3, providing a minimum 12 months’ storage.”

The system’s so simple everything flows by

means it can move and flex with the pond’s setgravity through the weeping walls all the way tlement. The site formerly sloped down, so one to the pond – there’s no pumps.

With no solids in the pond, there’s no need to side’s embankment was built up seven metres.

“The elasticity allows for ground settlement stir it – significantly reducing power consumption – and irrigation equipment can’t block and and weight of containment, but also if there’s an earth tremor,” says Hamish. fail.

The secret is the liner’s seams are comAgFirst Engineering is also installing a compounded. “The seams become stronger than pletely-monitored effluent irrigation system.

“If we don’t safeguard ourselves for the future the rubber itself and combined with the pond’s design will last a long we’re going to have time.” to spend more The massive 16,000m3 deferred effluent Hamish, who is qualmoney, so we did irrigation pond designed by AgFirst ified in pond design the job properly Engineering and line with a PondCo liner. and construction, says so we won’t have Pondco provide a comto worry about it,” plete, detailed pond says Brent. excavation design – Pondco supplied “we won’t line a pond and installed an that isn’t up to spec”.

EPDM rubber ponPondco customdliner and all water designs liners to suit; and gas drainage. and more are pop“The pondliner ping up as regulations provides 16,000m3 tighten. of storage,” says “We can make liners managing director to suit the grounding Hamish Forbes. of the environment The liner’s 300 and use of the farmer – per cent elasticity no one can buy a good product off the shelf.”

AgFirst Engineering’s twin sludge-bed system with weeping walls, separating effluent solids from liquid – all natural with no pumps involved.

Brent Welch’s new dairy, with the feed pad in front.

WELCH EGG CO LTD

Page 48

Coast & Country

A dream come true lets, meaning no extra fittings are needed.”

And Devan Tanks’ customer service is second-to-none. “We deliver tanks when we say we will – and our drivers try their best to position them Six Devan tanks site beside the new dairy – exactly where and because Brent likes their durability and farmers want easy delivery there’s more than 20 on-farm. them.”

Brent says he sticks with Devan because their excellent.

“They’re value for money and I like how they can drop them off as they’re passing on SH2.”

Brent plans to have in-shed feeding. “Feed is the only thing that keeps cows flowing through the old shed – give them a lolly and they’ll keep coming in.”

Brent’s dealt with Takanini Feed for four years. They’re 10 minutes away – nice and handy. “The mill is just down the road. They supply palletised meal. We give up to 3kg per cow and drop back to about 1.5kg – depending on how AgFirst Engineering’s Waikato director Davieth Verheij, Reporoa Engineering much grass is about.” director John Perrin and GEA North Waikato/Northland area sales manager Takanini Feeds Ltd manuPaul Convery with Brent Welch at his new dairy. factures dairy pellets at its

Driving into the Welch’s, you can tell it’s Devan Tank country. “We’ve always used them,” says Brent, with 20-odd Devan tanks on-farm. Six 30,000 litre Devan tanks stand beside the shed.

“We want to catch rainwater because water is the next big problem – Waikato Regional Council’s variation six – so we have to start limiting water use and still do the same job.”

Devan Tanks general manager Jamie Lunam says water tanks is their core business with factories in Tauranga and Christchurch distributing products nationwide.

“It’s important rural customers know we supply stronger grade tanks people

use to store molasses, whey, colostrum – some even use them to hold liquid fertilisers.”

Devan’s point of difference is having the strongest tanks in the market, says Jamie. “They’re moulded with brass out-

ruminant mill at Mangatawhiri.

“We provide a pellet containing all the micros, magnesium oxide, vitamins and minerals etc which is balanced to give correct doses at the nominated feeding rate,” says owner Neil Burndred.

Nearly 100 per cent of Takanini Feeds’ clients have inshed feeding systems, ensuring total control over feeding rates – and total control over micros added.

The feed pellet is changed to reflect seasonal demand for energy, protein and feeding rate required.

“We find today’s farmers take much greater interest in what feed contains and we work hard to supply quality products designed for individual farm requirements.”

GEA North Waikato/Northland area sales manager Paul Convery with the Milfos cups on the 60-bail rotary platform.

The Reporoa Engineering milker pit, with GEA Milfos cups which sit off-ground and don’t get tangled in the platform bridge.

Harry’s pride

The dairy’s name hangs on a pink sign: ‘Amy’s Milking Parlour’ No 1. Est 1936.

Amy is Harry’s mother and the sign is a tribute to her and his family’s hard work.

‘Albert’s Eggs’ hangs above the family’s egg operation, to recognise his father.

“The opportunities we’ve taken are far beyond my wildest dreams – it shows what we can do as a family.”

By Merle Foster

Reporoa Engineering director John Perrin, with the milker pit, which sees people walk round-platform at the cows’ level and everything is contained – including cow crap.

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WELCH EGG CO LTD

Page 49

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Page 50

Coast & Country

A larger farm meant a new dairy The attractive wave-roof design dairy shed and rectangular yard, built

by Dairy Tech.

Dairy Tech’s 49m by 18m rectangular yard and six-unit feed pad at Malcolm’s dairy.

With the option of two farms 10km apart or one large unit, Otorohanga’s Malcolm Reynolds chose the latter prompting a mammoth 60-bail rotary dairy build.

“I lived at my former farm over the hill for about 35 years,” says Malcolm, who with wife Pauline has lived in Otorohanga since 1977.

His first farm was 108 hectares, which he sold and bought another 90ha to add to 163ha he’d bought five years ago to make a 254ha block, beefing up to a 1000-strong Friesian-cross herd.

Malcolm says the 60-bail rotary dairy project began in January 2013, with son Simon Reynolds’ helping with earthworks. Construction began in May 2013 was finished September 2013.

Something different

Malcolm didn’t want an octagonal shed. “I wanted something a bit different.”

Taking a ‘research drive’ with Dairy Tech owner Peter Gray to a wave-design shed, the

Pumpn owner Shane Phillips, in front of the water set-up in Malcolm’s new dairy.

pair sketched a plan. “I wanted a more appealing workplace, something aesthetically-pleasing, smart and clean.”

Dairy Tech constructed the dairy from the ground up, including underground works, concrete and wave-roof building, installed a flood-wash system, backing gate, and built a 49m by 14m rectangular yard and six-unit feed pad, which Malcolm plans to roof.

Dairy Tech’s maintenance man Pita Tapara says the wave roof is one farmers are very interested in.

“The structure gives more room. There’s a toilet and store room next to the milk room and ample room for water cylinders and vats, plus an office.”

The dairy’s roof is 25m by 25m, stands 6.2m at its highest point and 2.2m at its lowest.

“It lets light into the dairy and in winter doesn’t get dark in the milking area,” says Pita.

A row of large windows keep it cool during summer.

Pita says you only push one button for the flood-wash. “It flows out the row of pipes and green water rushes out it’s gone in about two minutes.”

But the shed’s main features are longevity and future-proofing. “You’ve got to build something that lasts.”

No scrubbing

Modern Coatings Ltd owner Roger Farley applied acraflex fleck coating to pre-cast panel walls. “This gives an easy-to-clean and durable surface that can handle twice-a-day cleans and harsh cleaning products used in the dairy industry,” says Roger.

The decorative fleck enhances the dairy’s look and hides any imperfections. Applying acraflex, which comes from Specialised Coat-

Thompson Dairies

ings Ltd, to dairy walls for 20 years Roger’s seen it outlast its 10-year warranty.

Malcolm is stoked with how it looks – and more importantly how it cleans up.

“There’s no scrubbing involved; the dirt just peels off.”

Meeting water regulations

Pumpn owner Shane Phillips installed water pumps, cooler, yard-wash and effluent systems. Working for Malcolm for 10 years, Shane simply moved farms with him.

Shane says water is metered inside the dairy.

“Effluent is becoming a huge market because farmers need to keep up with regulations, which are evolving.”

Malcolm chose a slope screen effluent separator that sits above a concrete bunker, which muck is scraped into by tractor from the feed pads.

Effluent is pumped to the slope screen that separates solids, and liquid flows off to a pond.

“Basically you’re left with effluent called green water; it’s used for flood-wash, pumped back to two tanks.

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Page 51

Design makes hands-off farming easy “You can also pump raw effluent to pasture – so there’s two systems.”

Shane says the three-day storage pump system, large pump for pumping from the pond, and small tanks on-site, give options. “It’s Malcolm’s design, and we’ve fine-tuned it.”

Malcolm went with sumps and pumps and separators in case he increases the herd.

“With this you just pump water; nothing else changes.”

He also likes recycling water. “We use about 30m3 of fresh water daily. The two 25,000m3 flood-wash are let go six times daily, saving 150m3 of fresh water – I actually haven’t got that water.”

Multi-purpose tanks

The two grey tanks holding fresh water for the new dairy are from Devan tanks. Malcolm says the tanks are crucial in storing the fresh water, using it for wash down and any other needs.

Devan tanks sales manager Alistair Bell says Devan tanks has a huge range of water tanks from 600 litres to 30,000 litres.

“The tanks are made from the strongest raw material available and carry a massive 20-year guarantee,” says Alistair.

“From the cowshed to the home garden, Devan has the tank to suit your situation.

perfect for storing molasses.”

The tanks also have a site glass, so farmers can see the exact amount inside to determine re-stocking; and with larger outlets, it’s easier to pump molasses.

“Having a Promax Molasses tank means farmers can have a bulk supply of molasses without having to worry about constantly re-stocking all the time,” says James.

Malcolm says while the amount of molasses the herd is fed varies from nothing to one litre per cow, “it’s a good to have a tank of the supplement on-hand”.

Tru-Test’s Dairy Technology Services Waikato area manager Dave Gray with the shed’s refrigeration system his company installed.

Chill – the milk’s cold

Devan tanks are used to hold recycled green water.

Successfully storing molasses

To feed molasses, Malcolm installed a Promax Plastics roto moulded bulk liquid tank.

Promax Plastics sales manager James Kirner says the tanks are known for super-tough durability, due to having corrugated walls - stronger than smooth-wall tanks. With a 20-year guarantee, tanks can be buried to one metre underground.

“They give farmers peace of mind, because they know they’re tough, high quality and guaranteed.”

James says molasses has a higher specified gravity than water.

“For example, one litre of water weighs one kilogram but one litre of molasses weighs 1.4kg – making it nearly half as heavy again, so it needs a tank with sturdy sides.

“Toughness of Promax Plastics molasses tanks make them

With milk cooling standards tightening, Malcolm addressed future changes now.

Tru-Test’s Dairy Technology Services installed a 13hp vat chiller and a 13hp Patton Pak refrigeration unit.

“It takes water down to six degrees Celsius, giving 11 degree Celsius milk-entry,” says Tru Test’s DTS Waikato area manager Dave Gray. He says now’s the time for farmers to update refrigeration. “If farmers are thinking of building a new dairy or renovating, they should be looking at extra cooling – not just on the vat – you’ve also got to attack it with chilled water or glycol.”

Tru-Test’s DTS installs both. “We’re flexible, we tailor-make systems – we talk to farmers, see what they need and make a package.”

Malcolm’s system has three options. “Farm water cools it initially; then the milk cooler chills the water, so milk entry is 12 degrees Celsius; then the chiller pulls it down.”

Malcolm also buried the concrete water tank, as an insulator, so the system’s more energy-efficient.

No wiring worries

Waipa Electrical Services’ Steve Foster and Paul Chestnut, Tru-Test’s Dairy Technology Services Waikato area manager Dave Gray, farm manager Mani Boparai and Malcolm Reynolds, at his new dairy.

After working for Malcolm for 15 years, it was natural Waipa Electrical Services’ Paul Chestnut and Steve Foster wire the dairy.

The sparkies ran underground services, power to the milking plant, chillers, hot water cylinders, making everything work by the touch of a button.

THOMPSON DAIRIES

Page 52

Coast & Country

New wave dairy for Reynolds’ farm Classic Builders building consultant Howard Baker with Jaspreet Boparai, who loves her new home.

The nine metre by 30m calf shed from Taylor Built Ltd offers maximum heat retention in winter.

Calves love the warmth of the new calf shed too from Taylor Built Ltd.

Otorohanga’s Malcolm Reynolds like being only ‘the boy’ round the farm these days.

Paul says they design electrical needs around how a farmer wants to use their plant.

“We put together the gear, make sure it works – and that it works the way the customer wants.”

Malcolm says Paul has a bent for electrical programming. “He takes care of it for me; I don’t have to worry about it.”

Cosy conditions

Malcolm built a new calf shed too, with Taylor Built Ltd creating a modern warm, cosy, light-filled haven for the farm’s youngest stock.

Taylor Built constructed a nine metre by 30m shed, with gutters both sides, and 3.5m high tanalised poles.

“Timber was chosen because it’s more resistant to possible corrosiveness of animal urine,” says Taylor Built managing director Lindsay Hamer.

Most impressive is the 200 micron Ultraflex plastic roof and gables, shaded 45 per cent, offering maximum heat retention in winter.

“The white allows more light through than solid roof cladding materials, creating warm and drier conditions inside,” says Lindsay.

“Animals seem to love the cosier conditions.”

Malcolm says the roof is plastic which lets the sun go through, keeping the shed light and warm.

“It means we can keep calves out of the weather, and it makes it easy for feeding them as well.”

A blissful home

When farm manager Mani Boparai and wife Jaspreet started work for Malcolm, they lived in the old farm cottage.

DAIRY TECH

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Thompson Dairies

Malcolm knew a new house would retain his effective manager. Liking his sister-inlaw’s Classic Builders’ home, he approached the builders. The new home overlooks the farm.

CB building consultant Howard Baker says the 257m2 four-bedroom plus-study home has a three-car garage for farm vehicles.

Howard says Classic Builders work with farmers to build homes fit for rural purposes.

“That’s the best thing about us – we can personalise it. Our design team altered this kitchen, opening it to stunning views.”

Sending staff to many remote places, there’s no travel-factor in Classic Builders’ prices – and they research beforehand, “allowing us to build quickly and efficiently, meaning less impact on the farmer”.

Jaspreet Boparai says her home is well-insulated, warm and easy to maintain.

“I’ve spent one winter in it – and its bliss.”

The ‘boy’ is happy While building the dairy, 850 cows were milked in an old herringbone – Malcolm calls a nightmare. “It was nearly 24 hours-aday, starting 4.30am and shutting down at 10pm.”

But he says it was worth it – he built something different with attractive staff benefits.

With good labour increasingly harder to find, Malcolm’s happy the dairy is easy to use – so he can continue being hands-off. “Mani manages this farm day-to-day; I’m the ‘boy’ round here.”

By Merle Foster

www.dairytech.co.nz DESIGN, CONSTRUCTION & AUTOMATION °°°° > }ÊÞ ÕÀÊ LÊi>à iÀt ÊÜi Ê`ià } i`]ÊÜi ÊV ÃÌÀÕVÌi`Ê }Êv>V ÌÞÊ ÃÊVÀÕV > Êv ÀÊ >Ê«À wÌ>L iÊ`> ÀÞÊv>À ÊLÕà iÃÃ°Ê > ÀÞÊ/iV Ê«À Û `iÃÊ`> ÀÞÊ `ià } Êà ÕÌ ÃÊ> `ÊV ÃÌÀÕVÌ Ê Ìi}À ÌÞÊÌ >ÌÊÜ Ì ÃÌ> `ÃÊÌ iÊ VÀi>à }Ê`i > `ÃÊ vÊ`> ÀÞÊv>À Ê > >}i i ÌÊ Ê> Ü }ÊÞ ÕÊ Ì Ê>VV `>ÌiÊ >À}iÀÊ iÀ`ÃÊ> `Ê «À ÛiÊivwV i VÞÊ ÊV ÜÊ y ÜÊ> `Ê Þ} i VÊ }Ê«À ViÃÃið

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Coast & Country

l McGill, Kiwitown Waikato Milking Systems’ Pau ’s Jeremy Collett, farm Electrical’s Daniel Neil, Qubik farm owners Zach manager Craig Walker, with rew Coombe.

And Mounsey and Anita and

Rustic Dair ies’ built by Wa new parlour and yard s, ikato Dairy Builders.

Making farm manager a very happy man This is a dairy designed and built by professionals at the top of their game.

It gives excellent value for money – and has made one farm manager a very happy man.

In late 2011 Andrew and Anita Coombe, along with their son and equity partner Zach Mounsey, bought this 114 hectare drystock unit just south of Waitomo and set about converting it to dairy, which meant a new dairy parlour.

They wanted maximum efficiency for their dollar, so they did a lot of research.

Andrew, who’d put himself in a ‘moon boot’ and crutches, had plenty of time to identify the best option for them – a dairy built by Waikato Dairy Builders and fitted with a Waikato Milking Systems’ milking plant.

Making tracks

The site they chose for the new dairy is a centrally-located green field, so it’s a long way in from the gate.

This meant a lot of work for Mike Richmond from MC Enterprises to do just in constructing the track to the site before work on the dairy itself could even be started.

Mike excavated the effluent pond and levelled the building site while Te Awamutu-based Bradfields Cartage brought in metal, sand and fill for the tracks and the building’s foundations.

Bradfields normally service the rural community through their main role in fodder and crop production and cartage, but moving sand and metal has become a large part of their business.

Building smooth flow

While Mike and Bradfields were getting the access and site sorted out, Waikato Dairy Builders was looking at the farm’s parameters – herd size, cow flow, worker comfort and safety, budget and all-round efficiency – to ensure the 32-aside herringbone dairy complex they’d designed would meet expectations.

They’d included an extended pit for future expansion to 40-aside and their innovative Ezi-Flo Pit Gates, a Waikato Dairy Builders invention that’s exported around the world, and a large amount of room around the bail.

All features are major contributors to the dairy’s smooth cow flow.

A long, gabled roof covers the bails and pit alongside a separate centrally-located building that houses the milking plant and office/smoko room – all separated by the tanker track from

By Graeme Dobson

the pump room, which is housed in a separate building opposite the vat stand.

Isolating the pumps to keep the work area very quiet is just another of the Waikato Dairy Builders innovations they offer their clients.

It’s this combination of innovation and simplicity, born from experience, that enables Waikato Dairy Builders to complete most dairies within five weeks – allowing ample time for other contractors to do their work.

High-performing gear

In this case it allowed Qubik quick access to install the new Waikato Milking System.

Qubik are long-standing authorised dealers for Waikato Milking Systems.

Andrew and Anita chose a range of equipment from Waikato Milking Systems to maximise efficiency.

They can easily add more technology devices later if they choose to, as Waikato Milking Systems’ products are designed to be modular, high-performing and easy to use, says Waikato Milking Systems North Island sales manager Paul McGill.

“A benefit of Waikato Milking Systems’ technology is that it is all designed to integrate seamlessly,” says Paul.

Shane Phillips from Pumpn.

The pump room.

Innovative Design Improves Efficiency Ezi-flo pit gates completely clear exit ways and cannot be touched by cows leaving the milking area.

The fully galvanised gates are available in kitset for speedy installation

0800 226974 2 C OW S H E D Ph Jim 07-850 5971 Mob. 0274 936 693 Ph Chris 07-849 3630 Mob. 0274 936 692 P.O. Box 10 188, Te Rapa, Hamilton www.dairybuilders.co.nz

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RUSTIC DAIRIES

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Page 55

Moon boot researcher finds best design to three vans on the road, servicing a mix of rural and domestic clients.

Like the rest of the dairy, his job was pretty straight-forward with nothing out of the ordinary, except the variable speed effluent pump.

“I promote variable speed pumps because of their safety features and power savings,” says Daniel.

“They cost more to put in, but they save about 30 per cent on power – that’s a couple of grand over ms. ar g in sw a year. And there’s less s m’ ste Sy g Waikato Milkin maintenance, so they pay for themselves pretty quickly.”

Qubik installed a Waikato Milking Systems’ modular Supa4 herringbone Coating on quality Dairy Wall Coatings Ltd, the South milking system with Swing Arms, Waikato Franchise for Specialised Waikato 320 claws and G2 cluster Coatings, applied an Acraflex sealing washers. coat to the pit walls, giving them For efficiency they added a Blower a long-lasting, hard-wearing and Vacuum Pump BP400 and a Smartattractive finish.

PULS digital pulsation system, also Acraflex makes maintaining a high from WMS. hygienic standard easy by sealing They also have a SupaFlo milk surfaces against bacterial build-up pump with a variable speed Smartand presenting a very easily cleaned DRIVE milk pump controller, and surface. a Milk Recovery System that sends a Specialised Coatings holds the sole pulse of compressed air through the NZ licence for Acraflex, which they milk lines after milking to push the remaining milk out before the wash. manufacture in their Auckland plant It’s an all Waikato Milking Systems’ to supply their franchises throughout plant – and all in all a unit giving the country. maximum return for outlay.

They’re rightly very proud of their Electrical installation was by product and back their confidence another local tradesman, Daniel Neil with a 10-year warranty on all new from Kiwitown Electrical. dairies.

Daniel established Kiwitown in The quality of the products, 2000 and his business rapidly grew together with Specialised Coatings’

commitment to service, keeps all franchises busy – and Acraflex is in a very large percentage of new dairies throughout the country.

Liquid innovators

Outside Shane Phillips from Pumpn undertook installing both the effluent system and water reticulation for the dairy and farm.

Shane has a reputation for taking the efficiency of the farmer’s operation seriously and he and his crew at Pumpn are innovators that, provided it involves liquid, seem to be able to do anything for the farmer.

They only work with the best equipment and if they encounter a situation where nothing available measures up, they design and manufacture it themselves.

According to Shane this was a big job, but a pretty straightforward one.

The reticulation is all controlled from the pump house, where an array of taps can direct water, complete with minerals, from Shane’s injection system anywhere across the farm.

“The effluent system gravity feeds from the dairy down to a pair of weeping wall pits that strain out the solids – used consecutively they last a season before they need to be emptied – and on to a 36m by 36m The view of the da by 3m deep green iry from the isolate king plant d The building housing the mil water-holding pond pump house. . ted loca lly tra cen is ce and offi lined with a Viking Containment geosyn-

Proven Designs, Proven Profits Waikato Dairy Builders are specialists in the design and construction of herringbone dairy sheds.

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WAIKATO DAIRY BUILDERS

www.dairybuilders.co.nz

thetic liner,” says Shane. “From there liner, which can occur if a small leak it’s pumped out to the paddocks via a ever develops.” shore-mounted multi-stage Reid and It took the Viking team-of-three Harrison pump with flow meter and less than two days to install the liner shore-mounted pond stirrer.”

– quick and efficient.

Shane performed all of the comLike Viking, all the contractors plicated equations needed to design Andrew, Anita and Zach employed a pond that meets both the farm’s are at the top of their respective needs and complies with all council’s games – and produced a job they can environment regulations. be proud of.

He then passed the design to Kevin It’s one that’s made farm manager Hinton, who is Viking’s North Island Craig Walker a “happy” man. sales representative, to make and

By Graeme Dobson install the liner.

Kevin says Andrew’s pond liner came in eight metre-wide strips that were shaped and welded together on-site. “After welding, each joint was pressuretested as part of quality assurance that lets us give our 20-year warranty,” says Kevin. ds, “For added security we A season’s worth of effluent soli for dy rea d install gas venting to prevent ove rem be to waiting ballooning [whaling up] the new season. from gas build-up under the

226974 2 C OW S H E D

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RAMUL FARM

Coast & Country

The way ahead for the hands-on farmer The rain has come, well sort of anyway, and the Waikato and King Country are beginning to green up at last.

A bit late for some, but for dairy farms like Tony and Yvonne Ralph’s 200 hectare property in the hills west of Otorohanga it promises a spurt of growth before winter.

Tony readily admits ‘marginal country’ is one way his property could be described and only part of it can be used for dairy – but the Ralphs are making it work.

In fact, they’re so confident in the land they bought a neighbouring 88ha block, and increased the herd to 450 and built a new dairy.

Tony did his homework; he looked at new dairies in the district and talked to other farmers. He knew exactly what he wanted.

Ramul Farm

Always the best “When I got serious I went looking at a lot of new dairies and Gibson Rural always came out with the best herringbone,” says Tony.

“It would have cost me $150,000 more to build a rotary this size, and lots of people have said ‘don’t build a rotary for less than 600 cows’.”

Gibson Rural Builders design and build rotaries and herringbones, but for a herd of Tony’s size the herringbone was the most cost-effective option.

So Tony sat down with Brent Bird and Blair Atkinson, directors of Gibson Rural Builders, and worked out exactly what he needed.

Both Brent and Blair have a long history with Gibsons; they completed their apprenticeships in the company under Pat Gibson, then became partners in 2006 and 2008, and finally bought Pat out when he retired in April this year.

They have several basic design options, but they redraw each dairy individually to take into account the site and the farmer’s specific ideas.

Tony, Yvonne and their cast of thousands that got the dairy up and running.

ID and view of whole dairy.

For example, for Tony they put a ramp into the pit instead of the usual steps to make it “easier on my legs,” as Tony explains.

They can do all sizes of dairies. Their biggest herringbones so far are a couple of 50-asides. They project-manage all of their jobs and do the entire infrastructure, from the yards to effluent ponds.

Top technology

When it came to fitting the dairy out, Tony had no hesitation; he went straight to GEA Farm Technologies.

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RAMUL FARM

Page 57

Ralphs make land and dairy work for them “I’ve milked in a few sheds in my time and I’ve always been impressed with WestfaliaSurge brand,” says Tony.

“I looked at other machines when I started looking at dairies seriously, but I still believe they’ve got the best technology,” said Tony.

And they’ve got the experience; WestfaliaSurge has been in dairies around the world since 1926 and hold a reputation as leaders in technical innovation and cost-effective, integrated milking systems.

The last few years have seen an integration of several leading companies under the GEA banner, including WestfaliaSurge with its innovative products seen as pivotal in the development of the dairy industry.

But Tony wasn’t after all of their high technology; he just wanted a good, reliable, efficient and userfriendly dairy.

“I’m not interested in all the computers; I trust myself and in a herringbone, in the pit, you’re always looking at the cows,” says Tony.

Paul – you don’t get a better endorsement than that.

Hayden didn’t just install the plant, he worked with Dave Hewson, who is the area manager for Mount Maunganui-based FIL (another GEA subsidiary), to ensure it will be kept clean well into the future.

High sanitation

Hayden Aymes from Dairyworx and Paul Gilling from GEA discuss the GEA WestfaliaSurge plant they installed.

No over-milking

Tony got what he wanted with WestfaliaSurge’s basic system, says Paul Gilling from GEA FT. “Tony’s gone for swing arms for superior cluster alignment and cup removers for efficiency. In a shed this size with only two people operating, cup removers stop the cows being over-milked and keeps the somatic cell count down.

“He also has a variable speed pump to reduce power consumption. Everything else is standard, but it’s wired for future additions if he wants them.”

Otorohanga-based Hayden Aymes’ Dairyworx Ltd is the local agent for GEA FT, so it was Hayden and his crew that installed Tony’s plant.

Hayden works very closely with both GEA FT and his clients.

“We’re doing three or four dairies with Hayden this winter and he’s an absolute pleasure to work with,” says

Dave worked out the rates of application for the detergents, acids and liquid alkalis, and the volumes of hot water that would be needed to keep a dairy of Tony’s size at the high degree of sanitation demanded by the industry.

Hayden then set the automatic system to Dave’s recommendations and FIL supply Tony with all the detergents and chemicals he needs.

Starting next season FIL will also be supplying Tony with teat spray.

“As well as the antibacterial action, our teat sprays have emollients such as lanoline that ensure the teats are maintained in good, soft condition,” says Dave.

But Dairyworx didn’t stop at installing the plant and sanitation, they also installed the refrigeration unit and all the water works in the dairy.

“We customised all the manifolds in the pumps to suit the set-up here. The whole system is individually designed, including putting all the pipes above ground as per Tony’s requirement,” says Hayden.

“There’s some horror stories about pipes blowing under the concrete. Other than that, it’s all pretty straight-forward.”

Power-saving refrigeration

Brent Bird and Blair Atkinson from Gibson Rural Builders.

The refrigeration plant Hayden installed was supplied by Te Awamutu-based Power Chill NZ Ltd. Power Chill’s director Robin McGregor says they supplied Tony with a glycol rapid cooling unit “that brings the milk down to 10-12 degrees Celsius before it enters the vat”.

“Then it’s chilled to six degrees Celsius within two hours to meet the new regulations that will come in in 2016,” says Robin.

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RAMUL FARM

Coast & Country

When doing your homework pays off “Like all our units, Tony’s was custom-built in our Te Awamutu factory. We source all our components locally, so parts are always immediately available.”

Robin says they design each unit for maximum power efficiency and reliability.

“It’s a matter of tailoring to the farmer’s needs, keeping it simple and making it bullet-proof. We make power savings because our units’ efficiency allows us to keep the motor size down – Tony’s got a six horsepower – so the farmer doesn’t have to upgrade his power supply.

“The heat recovery unit we supplied Tony also saves him power by preheating water to 55-60 degrees Celsius,” says Robin. “We make, supply and stand by everything, from the stand to the sticker.”

for up to 10 years.

The Pitmat’s not the only bright spot in the dairy, but Dairy Wall Coatings Ltd did a pretty good job as well when they applied an Acraflex coating to the pit walls.

Ever practical, Tony wanted a long-lasting, hardwearing and attractive finish in the pit – and that’s exactly what he got.

Acraflex is specifically designed for the dairy industry to maintain high hygiene standards by both sealing surfaces against bacterial build-up and presenting a hard-wearing and very easily-cleaned surface, and they put a 10-year warranty on all new dairies for added peace of mind.

Ramul Farm

Hillside heavy lifting

Anti-slip pitmats

Tony has added a touch of colour – blue and green – to brighten up the dairy, but it’s not just for appearance that he installed Numat Industries rubber Agrimat Pitmat in the pit. Pitmat provides a cushioning that reduces the stress on the body, especially the feet, legs and back that comes from long hours on hard concrete, and Pitmat’s ergonomically anti-slip properties make for a safer working environment.

As well as its health and safety benefits, Pitmat is warmer underfoot and makes a quieter, all round more pleasant working environment.

Maintenance is not a problem, AgriMat herringbone pitmats withstand most detergents and chemicals and cleaning is a simple hose down, but if a major clean-up is required they can be easily lifted out.

The mats themselves are made out of mostly recycled rubber and are tailored to fit each dairy, from design to installation.

According to Numat’s policy: ‘it’s got to be right first time, every time’ – and they’re so confident they get it right they guarantee product and installation

Numat Industries pitmat and Dairy Wall Coating’s paint-job make the pit brighter and user-friendly.

But before builders and painters or anyone else could even begin, an awful lot of earth had to be moved to provide a level site.

Tony and Yvonne’s property is not exactly flat by anyone’s standards and finding a level site for the dairy was virtually impossible, so they got local man Bruce Tait and his 12 tonne digger and bulldozer to do the heavy lifting.

Bruce had to shift some of a hillside down a bit, then cart in about 3500m3 of fill to build the outside of the site up and raise the race ways to and from the new building.

Once the dairy and yard site was ready for the builders Bruce moved down the hill a bit further to excavate an area to install the ‘weeping wall’ effluent pre-treatment ponds, then a little further down he dug out the effluent sump.

Solving water woes

Gibson Rural Builders and Pumpn’s weeping wall effluent treatment pits.

A crush bail is incorporated into the construction.

Shane Phillips from Pumpn worked with Dairyworx to sort out the effluent movement around the complex system. The farm’s contours were a considerable challenge, but one they were well up to.

Your local milking machine and dairy shed specialists

Hayden Aymes 0800 329 679

9 Lawrence Street, Otorohanga hayden@dairyworx.co.nz

We are your local farm refrigeration specialists:

¬ New installations ¬ 24 / 7 on call service ¬ Specialist on farm consultancy advice ¬ Preventative maintenance programme (no contracts) ¬ Digital thermometers fitted to vats ¬ Latest advice on technology advances

Call us to discuss your farm refrigeration needs

0800 868 250 Contact Robin McGregor for on farm consultations and qualified installation service 07 871 8229 Ι 437 Rickit Road Te Awamutu

PH 07 578 0030

RAMUL FARM

Page 59

Making a user-friendly, functional dairy The main problem was while there was enough space downhill from the dairy for the weeping walls to strain out the solids from the effluent and a concrete sump for the green water, there was no flat area nearby big enough for a storage pond.

Normally, effluent would gravity-feed down through the weeping walls and into a 75,000 litre concrete sump then be pumped from there onto pastures.

But inevitably there would be times when rain would overtop the pond or make it impossible to pump onto the land, so storage was vital.

The solution was to put an enormous four million litre retention pond on top of a nearby hill and use one of Shane’s patented non-return valves to control the flow between the pond and sump.

Excess water is pushed uphill to the pond and be allowed to gravity-feed back to the sump and pumped to the pastures by a huge 20hp pump when conditions improve.

It’s an elegant solution to a ticklish problem, but one needing the best workmen and gear to work.

Shane uses only the best equipment, and if the gear isn’t there to meet the client’s requirements they design and manufacture it themselves – like Shane’s patented the non-return valve.

The constantly-changing farming industry has provided plenty of opportunity to test their initiative, and the initiative and commitment to high standards and customer satisfaction has made Pumpn leaders in their field.

since environmental regulations became stricter and he works closely with experts like Shane and pond liner manufacturers and installers, such as Pondco, to ensure the best possible outcome.

All Pondco’s liners are individually designed by Pondco’s director Hamish Forbes. But before he could design the liner, Hamish got together with Shane and Paul to design the pond itself.

They took into account things like soil-type, compatibility with the irrigation system, water and gas drainage, leak detection and compliance with all the regional council’s environmental regulations to come up with individual designs to suit each client.

Gibson Rural Builders built the dairy and yards.

Making ponds perform The groundwork needed to create the huge pond high on the hill was done by Morrinsville-based earthmoving contractors Paul Steiner Contracting Ltd. Paul has a large range of earthmoving and haulage equipment, including a long reach excavator that’s kept pretty busy constructing effluent ponds.

Ponds have become a major part of Paul’s business

Shane Phillips from Pumpn, with his innovative effluent reticulation system.

Strong liners

Then Paul dug the hole and contoured it ready for the Pondco liner. The Pondco team of five highly skilled and qualified installers arrived to fit the liner in the 39.5m by 39.5m by 4.5m pond – it took them just a day start to finish – and finally Shane connected the whole system together.

“The liner came in four panels, which were laid out and welded on-site,” says Hamish. “The panels are welded using a chemical process, then a secondary strip is welded over the top of the joint for added security. The result is very strong and all our liners have a 20-year warranty on them.”

Tony’s pond is an example of the ‘big stuff ’ that Pondco do, but they put the same level of care into a backyard fish pond, a natural swimming pond or an underground storage tank – no matter what the size – if it needs to hold water they’ll make it.

This dairy is an excellent example of sheer efficiency that didn’t cost an arm and a leg. Everything in it works toward maximising production without sacrificing worker safety or comfort. There’s nothing extraneous, nothing that looks and sounds good but sits idle for most of the time for one reason or another. It’s the way ahead for the hands-on farmer.

By Graeme Dobson

Page 60

NEW FARM DAIRIES

Coast & Country

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NEW FARM DAIRIES

Page 61

Page 62

LAGOON VALLEY DAIRIES

Coast & Country

A bird’s eye view of the new rotary dairy shed at Lagoon Valley Dairies.

Lagoon Valley Dairies

When Craig Wing and his equity partners bought a farm at Luggate, near Wanaka, in Central Otago in April 2011, it was a sheep and deer farm covered with scrubby grass.

By Helen Wilson

The rotary dairy shed from the yard.

The large grain storage silos supplied by Hecton Products.

Situated beside the Clutha River, Craig could see that with long periods of sunshine, low rainfall – the average being 520ml – and irrigation, the land could be turned into a productive dairy farm.

It took 12 months to get irrigation consents from Otago Regional Council for the 380 hectare farm.

To provide an income during this time, Craig took on dairy grazing.

When New Farm Dairies visited in April 2014, there was a new rotary dairy shed, lush pasture to equal anything in the Waikato, and contented cows in good condition happily tucking into the plentiful grass.

“I do like to look after my girls, as a happy cow is a high-producing cow,” says Craig.

Although he grew up on farms, Craig was a

carpenter by trade and lived in Auckland for a while.

He didn’t want to stay in the city so worked on farms in the Waikato and Canterbury for four years.

He then had the opportunity of an equity share in Lagoon Valley Dairies and the position of farm manager.

“We decided to look to the future and build a 70-bail rotary dairy shed.”

“We milked 800 cows this season and intend to increase this to 1000 for the 2014/2015 season, so it seemed sensible to build a dairy shed to accommodate these numbers,” says Craig.

The timeframe for building the new dairy shed was very tight; the cows bought in were due to start calving at the beginning of August.

Nothing was a problem

From start to finish the dairy shed took 12 weeks to build.

Craig cannot praise the contractors enough.

Progressive Engineering and the builder, Paul Warren from Winton in Southland, were awesome, says Craig.

Inside the pit of the 70-bail rotary dairy shed.

“Nothing was a problem. The guys even wrapped up warmly and worked in the snow to get the job done.”

Builder Paul Warren was recommended by milking system installers Progressive Engineering, which has worked with Paul on several other dairy sheds.

Deciding to see for himself, Craig went and visited a couple of Paul’s other dairy sheds in Southland and liked what he saw.

“Our dairy shed was a similar design to the ones I looked at, except this one is facing west to provide shelter from the prevailing winds.”

“The dairy shed is central to the farm so the cows have the minimum walking time to the dairy shed.”

“The inside walls are made from freezer panels, which are easy to keep clean, and the high roof allows for ventilation and lets in plenty of light,” says Craig.

“Paul did a tidy job and didn’t cut any corners, stuck to budget and finished on time,” says Craig.

Progressive Engineering has been committed to the dairy industry in the area for the last 25 years.

Helping turn Lagoon Valley Dairies’ vision into reality! waikatomilking.co.nz | 100% NZ Owned & Operated

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LAGOON VALLEY DAIRIES

The experts: Progressive Engineering’s Todd Hamilton, Waikato Milking Systems’ Southland and Otago sales territory manager Diego Brandao, and farmer Craig Wing discuss the merits of the new milking plant.

Craig Wing stands in the ya his new dairy shed on his Lu equity partnership farm

Equity buy ditches sheep and deer for dairy Based in Invercargill and with the growth of dairying in Central Otago, it has since opened a branch at Cromwell called Progressive Central.

Progressive installers

Progressive Engineering is the Waikato Milking Systems installers for Southland and Central Otago.

Todd Hamilton, age 28, is in charge of the Cromwell branch.

“I pretty much do everything from making the tea to installing and maintaining milking systems to electrical work,” says Todd.

Todd is also a qualified electrician, qualified engineering tradesman, as well as a fully competent milking machine technician.

Plus, he also has experience in pumping and water reticulation, so seemed a logical choice to set up the workshop in Cromwell.

“We practise a ‘turn-key’ application,” says Todd.

“The farmer contacts us and we take care of organising all of the subcontractors, so the farmer is only dealing with one person.

“We had a very tight timeframe here but because we have a competent team to call on

we got the job done on time, and there was no budget blow-out,” says Todd.

The milking machine and rotary platform from Waikato Milking Systems has as much technology as the budget allowed for, but there is the option for Craig to add on as finances permit.

“I was really impressed with what I saw and after talking to WMS sales territory manager Diego Brandao I decided it was the way to go – and I’ve been extremely pleased with the choice,” says Craig.

and fall, enabling cows to be kept on the platform if needed.

Craig also has a SmartDRIVE milk pump controller, designed to make milk pumping and cooling more efficient, and a SmartDRIVE vacuum pump controller which saves up to 47 per cent of power.

“It’s a nicely finished dairy shed,” says Craig. And having Todd Hamilton of Progressive Central, a division of Progressive Engineering, so close means Craig can rely on an excellent back-up service, if needed.

One-person dairy

An essential tool

The 70-bail rotary dairy shed has been set up as a ‘one-person’ dairy shed.

It has a three-port wash gland so the milking machine doesn’t have to be stopped to connect the wash hose, which saves time and improves efficiency. Craig also has Waikato Milking Systems’ SmartECRs (electronic cup removers) that work with other WMS technology products to trigger an automated sequence of actions during milking.

In addition to automatically removing the cups at the end of milking, saving time and labour, they also trigger BailGates to rise

P

The Protrack drafting system by LIC was recommended and installed by Progressive Engineering too.

“This is an essential management tool for a large herd, as it weighs the cows each milking and lets me know if any cow is not thriving and they will be automatically drafted out to be treated,” says Craig.

Based at Invercargill, Hecton Products started in the 1970s supplying sheep farmers.

More recently it has been supplying dairy farmers with feeding systems in their dairy sheds.

The privately-owned collecting the mi

Farm owner and manager Craig Wing w gressive Central manager Todd Ham

Progressive Central manager Todd Ham with his fully equipped truck.

LAGOON VALLEY DAIRIES

Page 64

Coast & Country

Craig loves looking after his ‘girls’ “Once again I went with Progressive Engineering’s recommendation and installed a Hecton feed system,” says Craig.

“It’s a really good system and has a crusher, so I can crush my own grain, and a molasses pump which directs the supplements to the individual feed troughs on the platform.

Hecton Products owner/operator Aaron Bremner says cows are fed each milking, usually on the shoulders of the seasons – and two-thirds of their business is supplying feed systems to dairy farmers.

“Prior to that we were mainly supplying sheep-handling equipment,” says Aaron.

Each system is customised to suit the farmer’s requirement and can be installed in rotary or herringbone dairy sheds.

Lagoon Valley Dairies has

included three silos with capacity for 19 tonnes, 45 tonnes and 250 tonnes, and a 30 tonne molasses tank.

Employing three full-time staff, including Craig, next season there will be four full-timers at Lagoon Valley Dairies.

The cows are kept in two herds, so there is usually one staff member milking and one getting the cows in for each herd.

Hassle-free homes

“Because we are employing staff, we needed staff accommodation,” says Craig.

“We decided on a Genius Homes duplex, self-contained unit. It’s separate accommodation for two workers but under one roof.

“I believe that staff need their own private space after working together all day and this is the perfect solution.

Based in Timaru, Genius

Craig Wing with the irrigators.

Homes delivers prefabricated homes around the South Island.

“We take care of everything,” says Genius Homes’ sales manager Jeremy Richards.

“The homes are built in our factory and then delivered to the site fully completed. We organise all of the site works, provide free project management and make sure the whole process runs on time and is hassle-free,” says Jeremy.

Genius Homes has a large range of homes and many options, from a single bedroom 45m2 unit up to a four-bedroom 160m2 home.

“Because they are built in our factory there is minimum disruption to the farmer. We also have a fast delivery time of about 16 weeks, from signed contract to delivery of the home,” says Jeremy.

“Another major advantage is the farmer is not investing

directly in the land.

If the building is no longer required, it can be shifted to another location as it is only bolted to the foundations.”

“These are very hassle-free staff accommodation homes and Genius Homes is really a complete solution provider,” says Jeremy.

Craig and his wife Lisinda and two children, Jonathan and Ruby, are committed to their dairy farm and love the lifestyle Luggate provides.

“There is plenty of hunting and fishing in the area and the kids get to go skiing in the winter,” says Craig.

“It’s a bit of a micro-climate where we are and not as cold as would be expected. We have about three falls of snow a year.

Lagoon Valley Dairies Re-locatable accommodation, supplied by Genius Homes.

Waikato Milking Systems cluster.

The cows are mostly pasture-fed and kept outside – and with irrigation there is always lush green pasture.”

By Helen Wilson

Craig Wing and his well-fed cows enjoying the lush pasture.

LAGOON VALLEY DAIRIES

PH 07 578 0030

Page 65

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HITCHEN

Page 66

Coast & Country

Sheep to dairy - simple

Contract milkers Anton and Kate Malan, with Kate’s parents – farm owners Chris and Colin Hitchen.

Colin and Chris Hitchen’s 80 hectare, flat farm is near Winton in Southland – and for 30 years they were struggling sheep farmers.

The efficient circular yard.

The entrance way of the 40-aside herringbone dairy shed.

They needed another income stream, so Colin put his skills to good use and started up an engineering business nearby.

Chris ran the sheep farm and family home while Colin concentrated on the engineering business – and it wasn’t long before the engineering work was supporting the farm.

“In the 1990s the dairy industry hit Southland and the farming landscape started to change. About five years ago, a real estate agent rang me up to see if I would lease the farm to a dairy farmer. It was an offer I couldn’t refuse,” says Colin.

The lease agreement included re-fencing and re-grassing the farm – and very soon it started to look more like a dairy farm than a sheep farm.

“Our daughter Kate was overseas at this time and decided to come home and wanted a job in the outdoors,” says Chris.

“She got a job on a dairy farm nearby, where she met and later married Anton Malan. When our lease came up for renewal, we decided to convert the farm to dairy – and Kate and Anton decided to be our contract milkers.”

Now the day-to-day running of the farm is carried out by Kate and Anton with help from Chris milking and feeding the calves.

Colin and Chris are the relief milkers.

Colin still runs his successful engineering business, mainly making trailers. The farm

conversion was completed in spring 2013, just in time for the first-calving cows.

The first season they milked 200 cows with both Kate and Anton in the dairy shed. There are only five rows of cows, so milking is completed in super quick time.

Turn-key package

“I had known Chris Hughes from Progressive Engineering and had built up a good professional relationship with him over the years.

“Chris had just purchased a trailer from me and I invited him to give me a quote for installing a milking system in our new dairy shed. I couldn’t argue about the price and the quality of the Waikato Milking System, so they got the contract,” says Colin.

Progressive Engineering offered Colin and Chris their ‘turn-key’ package, taking care of organising the builder and all of the subcontractors.

Chris Hughes says this is a pivotal service welcomed by Progressive Engineering’s clients. “By taking the hassle out of having to manage the build, they can spend their energy and concentrate on taking care of other parts of the conversion – of which there are many.”

The builder, recommended by Progressive Engineering, was Paul Warren from Winton. He has established a reputation in the Southland/Otago area for building well designed dairy sheds within budget and on time.

“We decided to build a 40-aside herringbone dairy shed. We looked at a few of Paul’s other dairy sheds and liked what we saw,” says Colin.

Helping turn Colin Hitchen’s vision into reality!

0800 901 902

Industries Ltd

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HITCHEN

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Page 67

New income flows from dairy

“We called on Anton’s dairy farm experience and he suggested a few changes to the yard, and we made the roof higher to let in more light. Being an engineer, it was my job in the weekends to weld the yard rails.”

Peace of mind The 40-aside herringbone dairy has been fitted with a Waikato Milking Systems Loopline with SmartECR electronic cup removers, swing arms, SmartD-TECT for mastitis detection and a Hush Kit, which reduces the noise levels.

There is a SmartDRIVE vacuum pump controller and a milk recovery system, which means all the residual milk is recovered from the milk line. The swing-down jetters allow for easy cleaning of the milking plant.

“I wanted an efficient dairy shed that was high-end and easy to operate so the relief milkers – Chris and myself – would be able to step in and milk without too much trouble,” says Colin.

“As newbies to this game, I wanted peace of mind – and with a reliable milking system and excellent backup service from Progressive Engineering I have that.”

When doing research into what type of dairy shed to build, Colin grilled other farmers about advantages or disadvantages of putting in a Protrack system.

“Some had put it in at a later date and suggested to me it would be best to put it in at the beginning – and I’m glad I took their advice,” says Colin.

LIC’s Protrack system is an essential tool for farm management and allows the farmer to detect any health issues with cows before they develop into something untreatable.

The cows are automatically weighed and any needing attention are drafted out into a separate pen, and waiting for the farmer after milking.

The feed system was bought from PPP Industries from Tuakau – and Colin put his engineering skills to use, installing it himself.

“It works really well, the cows are automatically fed the required amount of supplements each milking,” says Colin.

The Clean Green Effluent Company from Invercargill installed the effluent system. “Once it was set up,

it just keeps going and I don’t have to worry about it,” says Colin.

Clean Green Effluent Company owner and designer Lindsay Lewis says there is very little disturbance to the ground with this system.

“The effluent is gravity-fed from the dairy shed into distribution tanks. The liquid is pumped out to 192 pods in the paddocks. There are 24 pods running at one time,” says Lindsay.

“They switch on for seven minutes, spray over a 15 metre diameter soaking in about 0.25ml and then switch to the next group of 24 pods in the next paddock.”

The solids left in the weeping wall are dug out about once-yearly and spread on cropping paddocks as fertiliser.

“The system has been developed for about seven to eight years; and it is suitable for large or smaller herds,” says Lindsay.

“It is such a new and simple design that requires virtually no work to operate and maintain.”

Colin says the effluent gets spread into the four paddocks “and the pods only need to be moved every month or so”.

Lindsay L ewis, owner of Clean Gre en Effluent C ompany, by th effluent p e onds.

Four sheep

There are only four sheep left on the farm and these are going to end up in the freezer.

The Hitchens have made a smooth transition from sheep farming to dairy farming by taking the best advice and using contractors they trust.

The last word comes from Colin: “The dairy shed is built for New Zealand farmers and is technically brilliant and very

By Helen Wilson simple”.

The milk tanker arrives to collect the milk.

The last row of cows waiting to be let out.

Kate Malan cleaning the milking clusters.

CREEKSIDE PASTURES

Page 68

Coast & Country

A Stirling effort to build new dairy The gentle, rolling slopes of Clydevale, near Balclutha, in the South Island is where Gary and Alison Stirling moved to from Canterbury.

The rotary dairy shed from the circular yard.

Waikato Milking Systems cluster.

Waikato Milking Systems’ Southland and Otago sales territory manager Diego Brandao and Chris Stirling stand outside the Stirling family’s new dairy.

It was a 185 hectare sheep and beef farm which they’ve converted to dairying in 1995-1996.

“To do this, we leased an adjoining 212ha next door, built our first rotary dairy shed and employed a sharemilker,” says Gary.

Five years ago their son Chris decided to come back on the farm.

He’d completed a Diploma in Farm Management at Lincoln University and then went to the United States for six months to work on a beef ranch.

He came back to New Zealand and worked on a cropping farm in Canterbury for two years. Following this Chris and his wife Sarah worked on sheep and cropping farms in Australia.

“We decided dairy farming suited us best and started by working for the sharemilker who was on my parent’s farm at the time,” says Chris.

When the sharemilker’s contract finished, Chris and Sarah took over

Cows enter the platform from here.

as managers with a small shareholding in the farm.

The leased land became available to purchase in 2012; so with an increase in land area and herd numbers, the rotary dairy shed in use became too small and wasn’t well located on the new farm.

The logical solution was to run the farms separately, and build a new rotary dairy shed in a central location on the new farm.

It has worked well – 450 cows are milked in the new dairy shed in two herds, with 300 put through the older rotary.

Nice and simple

The older rotary dairy had some Waikato Milking Systems equipment in it.

“It was nice and simple to use and anything not quite right it was easy to fix, so we decided to install a Waikato Milking Systems plant in this dairy shed,” says Gary.

Dairy & Pumps Gore Ltd is the Waikato Milking Systems agent for the area and Mark Hosie, one of the owners, was able to offer Creekside Pastures Ltd a ‘turn-key’ option.

“We offer the total package from start to finish.

The farmer is dealing with just one person and we use the sub contactors that we know do a good job and can be relied on,” says Mark.

The builder, Paul Warren from Winton, was recommended by Dairy & Pumps Gore Ltd, as he has an unenviable reputation for building quality, within budget dairy sheds, both herringbone and rotary.

“This was one of my standard rotary designs with a few modifications, such as a half wall where the hot water cylinders are in a corner of the building. Often there is a full wall, and a drop down vet stand, which takes up less room when not in use,” says Paul.

“It has a galvanised Rectangular Hollow Steel portal, which makes it bird-proof and the roof has extra Clearlite on it and there are a few more windows for extra light. The walls are freezer panel, which are easy to keep clean,” says Paul.

The size of the dairy shed is for a 54-bail rotary but has been fitted with a 50-bail platform, so there is extra room between the platform and the walls for ease of movement.

The new raceways formed by K D McKee Contracting.

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CREEKSIDE PASTURES The front of the Stirling family’s new dairy.

Gary and Chris Stirling with Dairy & Pumps Gore Ltd’s Mark Hosie, in front of the WMS clusters.

Paul Warren is happy to change his standard plans to suit the farmer’s requirements and also builds implement sheds, houses and does alterations. He employs eight staff and covers Southland and South Otago regions.

Waikato Milking Systems’ Southland and Otago sales territory manager Diego Brandao says the Stirling’s new dairy has a 50-bail Orbit concrete rotary platform fitted with a Waikato Milking Systems milking machine, with SmartD-TECT for mastitis detection, SmartECR electronic cup removers, SmartSPRAY automatic teat spray system, Fristam milk pump and SmartDRIVE milk pump controller.

“It also has a Hush Kit to minimise milking machine noise, a Milk Recovery System and G2 cluster washers. This is pretty much top of the range, but there is the capacity for adding on new technology if required,” says Diego.

The new dairy has been fitted with a Protrack Vantage system, which ‘talks’ to the Waikato Milking Systems’ SmartD-TECT in real time and instantly identifies a cow with mastitis. It is drafted into a separate pen, ready to be treated after milking.

Jared Cowley has been the farm’s electrician for many years and was part of the ‘turn-key’ recommendation by

Family dairy fits the purpose Dairy & Pumps Gore Ltd. Jared, who owns Cowley and McLaren Electrical at Balclutha, says this was a routine electrical system for a rotary dairy.

“I think the important thing is we provide a 24-hour seven-day back-up service for all our farmers. We also supply and install pumps,” says Jared.

Their work is not just rural, they can wire up commercial buildings and houses too.

No kicks

To save stress on the cows and the operator a Wrangler has been installed in the yard to restrain the cows when their hooves need trimming.

“I have one in the other dairy shed; it works well and I wouldn’t be without one.

It means we can attend to a cow without the threat of being kicked,” says Chris.

A lot of dirt gets moved around on a project like this and it takes someone who knows what they’re doing to get it right.

Kent McKee, of K D McKee Contracting at Clinton, is just the person.

He did the earthworks for the dairy shed site, formed the new raceways and standoff pads for the cows, and dug the effluent pond and drains for the pipes.

The spacious and practical tanker track

The 50-bail rotary platform.

The Protrack Vantage drafting system.

was formed by him as well.

Kent has been operating the equipment since the age of 12, and worked for other companies until forming his own. He has a good relationship with his clients and believes in “doing a job once and doing it right”.

Creekside Pastures is truly a family business involving Chris and Sarah as dairy managers, Sarah helping with rearing the calves in spring, while Gary keeps a watchful eye on everything and manages a 400ha runoff for sheep, beef cattle and dairy replacements.

Gary’s wife Alison also helps with rearing calves and daughter Claire, who lives in Wanaka, comes home to help out when needed.

“While this dairy shed was being built we were still running the other farm, so having someone like Mark Hosie organising all the contractors – it certainly helped,” says Chris.

“It meant I was only dealing with one person all the way through. They know the contractors and the products.”

This season the farm employs three staff, including Chris, and next year two staff will be stationed on each farm – with Chris overseeing both.

Helping turn Creekside’s vision into reality! waikatomilking.co.nz | 100% NZ Owned & Operated

Page 69

By Helen Wilson

Creekside Pastures staff: Farm assistants Sam Roker, Megan Jenkins and Woody Bokes, with farm owners Gary Stirling and Chris and Sarah Stirling, with baby Alice.

AUCHENBRAE

Page 70

Coast & Country

From meat to dairy - not scary Looking from the yard into the dairy shed.

Frustrated with the meat industry, Duncan and Nicky Anderson of Rotherham in North Canterbury decided in 2013 they could make better use of their farm called Auchenbrae.

two in the dairy shed, two bringing in the herds and Nicky and I help out when required.â&#x20AC;?

Future expansion

By Helen Wilson

The idea was to covert to dairy farming.

The 405 hectare farm was carrying 4000 breeding ewes, beef animals and dairy support for other dairy farmers.

Now there are 30 sheep and 1256 dairy cows milked during the peak of the season in a new dairy. â&#x20AC;&#x153;We had to consider farm succession and now the farm is accommodating seven families, instead of two families as a dry stock farm,â&#x20AC;? says Duncan.

Next season theyâ&#x20AC;&#x2122;re looking to milk 1400 cows in three herds. The fertile ďŹ&#x201A;at land is reliant on irrigation from the Waiau River and there are four centre pivots on the farm.

The Andersons have been shareholders in the Amuri Irrigation Company since 1979, which assures them their allocation of water each month.

The farm can get two-three falls of snow each year, depending on the season.

When New Farm Dairies visited in April, 300 cows were being dried off and the balance of the herd had shifted to once-a-day milking, due to weather conditions and to ensure optimum cow condition during winter.

Duncan has a mostly pasture management system with some supplement feed. â&#x20AC;&#x153;The dairy farm employs six full-time staff;

Rural Building Solutions is based in DarďŹ eld and specialises in building Chapman Dairy farm dairies throughout the greater Canterbury region.

Rural Building Solutions owner Nigel Hodges says Chapman Dairy has more than 30 yearsâ&#x20AC;&#x2122; experience designing and building dairy sheds, both rotary and herringbone. â&#x20AC;&#x153;Their designs have stood the test of time, make good use of space and have good cow ďŹ&#x201A;ow. â&#x20AC;&#x153;Rural Building Solutions are proud to be licensees of Chapman Dairy, which is a wellknown and highly-regarded brand of dairy parlour design. â&#x20AC;&#x153;We were pleased to build an 80-bail rotary farm dairy for Duncan and Nicky,â&#x20AC;? says Nigel,

The Waikato Milking Systems clusters. who says the Andersons decided on an 80-bail rotary to allow for future expansion of their herd.

Before converting to dairy, Duncan had been an ArtiďŹ cial Insemination technician and worked in several dairy sheds around the Amuri area, so when it came time to build his own dairy he had a good idea of what he required.

Good ideas

â&#x20AC;&#x153;I took all the good ideas from the dairy sheds I had seen and asked the farmers what they would change. â&#x20AC;&#x153;Nigel listened to my ideas, made some suggestions and we decided on a standard Chapman Dairy design with a few modiďŹ cations.â&#x20AC;?

PH 07 578 0030 The pit area in the centre of the dairy shed.

AUCHENBRAE

Page 71

Accommodating future farming

The building is closed in at one end, with a high roof with good ventilation and there are no tight corners so there’s plenty of space between the cows on the platform and the walls.

“This keeps the walls a lot cleaner,” says Duncan.

The walls are made of insulated refrigeration panel, which is standard in a Chapman Dairy design and is easy to keep clean. The bottom of the inside wall has been coated with a special resin paint by Specialised Coatings, which is aesthetically appealing, easy to clean and gives the building a finished look.

Tight timeframe

The project had a very tight timeframe. It was started at the end of March and Duncan was milking in it on July 24.

Nigel says Duncan’s shed was the last of

eight Rural Building Solutions built during this season.

“We had 14 men on-site and everyone did a great job. We value service, quality and honesty over volume. Delivering on time is most important to us and the farmer,” says Nigel.

The 80-bail rotary dairy shed has the latest Waikato Milking Systems technology, which was installed by James Silver Smith Limited – the Northern Canterbury dealership for Waikato Milking Systems.

Trevor Smith from JSS Ltd is a motor engineer by trade and has been in the milking machine industry for 34 years. Trevor says he’s certainly seen a lot of changes during that time.

“This large-scale, high-performing rotary is designed to milk large numbers of cows extremely efficiently. It has had an automatic platform oiling system installed, which is a prototype and maintains a constant supply of oil,” says Trevor.

Everything stops or starts with a push of a button.

This saves staff going down into the centre and topping up the oil all the time.”

Latest devices

The rotary also has many of the latest dairy technology devices including BailGate Straps that integrate with the milking system to keep the cow on the bail if she needs to go around a second time for milking, inspection or treatment.

The Waikato Milking System includes SmartECR electronic cup removers, SmartD-TECT for mastitis detection and SmartSPRAY automatic teat spray system on the platform.

There are two spray nozzles in each bail, which spray the teats immediately after the cow finishes milking.

The teat canals are still open, so the solution gets to the end of the teat canal, says Trevor.

“Consistent with today’s thinking the milk line has a larger diameter, which allows for

Helping turn Auchenbrae’s vision into reality! waikatomilking.co.nz | 100% NZ Owned & Operated

a faster, more efficient milking. There is a manual wash gland which drops down and washes the platform. “Allowance has been made to upgrade the system as the technology becomes available,” says Trevor.

Managing cow health

The dairy shed has LIC’s Protrack herd management system installed to help with managing cows with health problems.

“I wouldn’t be without it. It lets me know the condition of the cows and any that need attention are drafted out to be attended to after milking,” says Duncan.

Tru-Test’s DTS Milk Cooling Solutions from Christchurch, designed and installed the refrigeration system.

The large circular yard, with a tractor laden with silage in the background.

Page 72

AUCHENBRAE

Coast & Country

Success in switch to dairying “This dairy shed was a larger project, due to the size of the shed and all the gear in it.”

Tru-Test’s DTS area manager Anton Carr stands beside the refrigeration units.

Tru-Test’s DTS area manager Anton Carr says his team spoke to Duncan and Nicky to find their main objective was to futureproof the dairy shed for proposed changes in the milk cooling requirements. “What was installed now will be compliant with the new regulations in the future,” says Anton, who says the refrigeration system is performing well and the milk is kept chilled at optimum level for optimum returns.

Nairn Electrical has a branch in Rangiora and Leeston and has been Auchenbrae’s farm electricians for many years.

“Originally, we wired up the irrigation pumps and the centre pivots for the farm, so we had built up a good relationship with

Duncan and Nicky,” says Simon Francis, from Nairn Electrical.

“This dairy shed was a larger project, due to the size of the shed and all the gear in it,” says Simon, who says his team did all the electrical wiring for the effluent system, pumps and controls that operate the dairy shed. “Anything that required electricity to make it work, we did it.”

Nairn Electrical also provides and 24-hour seven days a week full back-up service.

Duncan says local man Bill Lott carried out all the site works. “He had to build the site up and make sure it was level before the work could be started. He also formed all the raceways and the tanker track,” says Duncan.

then to the meal silo. It’s a total ‘push the go button and walk away’ system,” says Steve.

Once the meal silo is full, everything shuts down in sequence for the next start up.

The product is augered from there into the shed and drops a predetermined amount of grain in front of each cow on the platform.

The drive motors are linked into Duncan’s herd management systems and the feed rate can be accessed on the computer.

Each cow can be fed the amount she requires to keep in good condition. Molasses can also be incorporated into the system and will again drop a predetermined amount with the grain.

The large effluent pond has been lined with a specially-designed plastic type liner by Viking Containment.

It stops the stored effluent leaching into the surrounding soil and causing contamination to the area.

“He did a great job. I started out using Bill’s father when he had the business and have continued using the same company.”

Bill did precision work, which made the building job easier and they used less concrete.

Builder Kelly Earl’s brother, Mike Earl, also helped with the earthworks at the beginning of the project. Sadly, he was killed in an accident before completion and is sadly missed.

Amuri Transport at Culverden carry all fertiliser for the farm.

Push-button feeding

The fully automatic grain feeding system was supplied and installed by Permbrand at Rolleston West.

Permbrand sales manager Steve Waters says the grain is stored in the main silo, which holds about 240 tonne of wheat or 205 tonne of barley. “It is augered to the mill and

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PH 07 578 0030

Auchenbrae

Two families now seven at Auchenbrae

The pumps for the effluent and water reticulation system were installed by Pump Services 2010 Ltd from Rangiora.

Kitset calf sheds

GreenWood from Christchurch has been designing and supplying calf sheds for almost 10 years and during this time has supplied hundreds of calf sheds of various shapes and sizes and specifications. This experience, combined with Duncan and Nicky’s requirements, helped to design and price their calf sheds as efficiently as possible.

The most design-efficient option was two GreenWood lean-to sheds. The contract for the supply of these large calf sheds was a competitive process, and GreenWood was chosen to supply the building.

Cows waiting in the smaller yard.

Page 73

GreenWood calf sheds have a very strong structure and are tidily built by Kelly Earl and his team, and will last many, many years. GreenWood also build cattle yards and farm bridges.

Kelly Earl Builders, from Rangiora, is an independent building company and often do contract work for Rural Building Solutions. This time they erected the kitset calf sheds supplied by GreenWood.

“The 15-bay calf sheds can hold 25 calves per bay, so a total of 375 calves in each shed. They are built to withstand the weather and provide good cover for the calves,” says Kelly Earl.

“The extra wall framing is a real advantage, as it will keep the walls stronger and straighter for longer.”

Kelly used to drive tractors and trucks but decided to go building after working overseas. Now in his seventh year of building, he was site manager for this project and is pleased with the way everyone co-operated and got on with the job.

Duncan says the contractors were all on the same page, worked in well together “and the end result is a modern dairy shed, which is easy to operate and work in and will accommodate our future farming requirements”.

Four new houses

What was once a dry stock farm is now Auchenbrae Dairy with an increase in staff numbers – and as is customary in New Zealand, farmers provide their staff with comfortable living quarters. Duncan and Nicky

Drystock-turned-dairy farmer, Duncan Anderson.

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have built four new houses on their property – all built by Rotherham builder BG Beaven Builders Ltd. The new houses comprise of one four-bedroom house, a three-bedroom house and two houses with two bedrooms. Barney Beaven has been building houses in the area for 33 years and is highly sought-after.

“We now have our own architecturally-designed house plans, which we can modify to suit the client’s requirements,” says Wendy Beaven, who helps run the business.

There were 10 builders working on the houses and they took five months to complete; just in time to start the new season. Duncan says it’s much easier to attract good

staff if the farm accommodation is of a high standard “and that’s why we chose Barney Beaven; he has a good reputation around the area”.

Converting to dairying from drystock farming has been a successful challenge for Duncan and Nicky.

They’ve completed their first season and now look forward to expanding their herd for the next.

By Helen Wilson

Kelly Earl and Duncan Anderson stand in front of one of the calf sheds.

JSS Ltd’s Trevor Smith, farm owner Duncan Anderson, builder Kelly Earl, Rural Building Solutions’ Nigel Hodges, Permbrand’s Steve Waters and Tru-Test’s DTS area manager Anton Carr.

TE AWA LAND CO

Page 74

Coast & Country

Loving new dairy - even on a cold, wet, windy day a The backing gate with ic at tom Dungbuster Au Yardwashing system.

The solar powered backing gate.

The new dairy on the Schrider familyâ&#x20AC;&#x2122;s Te Awa Land Company farm near Temuka in South Canterbury has already won the heart of the propertyâ&#x20AC;&#x2122;s production manager Courtney Menzies.

By Helen Wilson

â&#x20AC;&#x153;I love this new dairy shed. The cows ďŹ&#x201A;ow in and out smoothly; itâ&#x20AC;&#x2122;s quiet and easy to keep clean,â&#x20AC;? says Courtney, who reckons a lot of thought has gone into its design. â&#x20AC;&#x153;Noel Schrider and his son Brent Schrider have made an effort to work out what works best for a rotary dairy shed,â&#x20AC;? says Courtney, who has been the production manager since June 2013.

She looks after the dairy, cow production and pasture management and then reports back to Brent.

Judging by the condition of the new dairy and the farm sheâ&#x20AC;&#x2122;s doing a great job and enjoys her work â&#x20AC;&#x201C; even on cold,

wet, windy days.

The farm is 290 hectares with 275 hectares effective, milking 490 cows and up to 670 cows during the peak of the season.

Courtney tells New Farm Dairies there hadnâ&#x20AC;&#x2122;t been much rain during summer. â&#x20AC;&#x153;And there were only 12 paddocks with irrigation, so we had to reduce the cow numbers and decided to send them to the Schriderâ&#x20AC;&#x2122;s other farm for the rest of the season.â&#x20AC;?

The farm was originally bull beef and grazing but at the end of 2012 the Schriders started converting to dairy.

They already had a dairy farm next door so were able to use their experience gained from that development in making the second conversion a lot smoother. The two farms are run completely separately.

Tried and tested

Brent had been very impressed with the performance of the Waikato Milking Systems plant in his other rotary dairy shed and decided heâ&#x20AC;&#x2122;d stick with what was

This is the ďŹ rst of the new generation tried and tested. The South Canterbury dealCentrus composite platforms in the 60-bail ership, Waikato Milking Systems Timaru at conďŹ guration installed in South Canterbury Washdyke, installed the complete plant. â&#x20AC;&#x153;We have provided a back-up service for the and has proved to be a good choice.

Mark says Brent opted for a high performother dairy shed, so Brent approached us to install the milking machine for this one,â&#x20AC;? says ing Waikato Milking Systems Smart package, which includes Smart-ECR electronic cup Mark Wilkes, who owns Waikato Milking removers, SmartWASH, which is an autoSystems Timaru with his wife Sue. matic washing system, and SmartSPRAY â&#x20AC;&#x201C; an The 60-bail rotary has a Centrus composite automatic teat spraying system. platform, which is 80 per cent lighter and The South Canter bury dairy shedâ&#x20AC;&#x2122;s ďŹ ve times stronger yard on a wet day. than a concrete one â&#x20AC;&#x201C; and it saves a lot of wear and tear on the running gear.

It has a 2.7 metrewide deck with rubber matting constructed into it, which gives it a smooth, easy care surface and adds to cow comfort.

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PMR Grain Systems’ sales manager David Shaw, with the grain system.

TE AWA LAND CO

Te Awa Land Company production manager Courtney Menzies and Mark Wilkes, Waikato Milking Systems Timaru.

Page 75

Everything is done at the push of a button.

Waikato Milking Systems clusters.

South Canterbury dairy keeps Courtney happy The SmartSPRAY system sprays the cow’s teats at the optimum time after she finishes milking and before she exits the platform. This helps to combat mastitis.

Waikato Milking Systems Timaru has five installers who are kept busy with the many conversions happening in the area. They also provide an excellent 24-hour, seven days a week back-up service.

Easily identifying cows

The dairy has also been fitted with Protrack’s Vantage system for rotary dairy sheds and provides in bail cow identification.

The cow is automatically identified as she steps onto the platform and the information is displayed in real time on a monitor at cupson or cups-off.

The cow’s number comes up on a screen, so there’s no need to look for the ear tag while milking.

Protrack can alert milking staff with any

information about the cow such as antibiotic treatment, reproductive history and the somatic cell count from her last herd test.

It can also be programmed to allocate the required amount of feed for each cow depending on weight or production and eliminates wasting feed on cows that don’t need it.

Wireless backing gate

An innovative backing gate completes the smooth running of the dairy shed. It was designed and provided by Cullimore Engineering Ltd of Ashburton.

The wireless backing gate for the large rectangular yard has two large batteries, which are charged by solar panels – and even after a week or more of overcast conditions will still operate at full potential.

It operates on a low voltage system, which eliminates stray voltage that can cause stress on cows in the yard. Being wireless-controlled means there are no cables attached to the gate.

“The solar powered, wireless-operated backing gate operates efficiently and there are no unsightly cables to get tangled in. I can see these becoming more popular in dairy sheds,” says Brent.

“It’s very versatile and Brent has realised the benefits of having a reliable automatic feed system that cuts out the worry of whether each cow is getting the required amount,” says David.

Individual feeding

Cool system design

PMR Grain Systems at Hinds in Canterbury offers a complete grain storage and distribution system for dairy sheds.

PMR Grain Systems sales manager David Shaw says his company installed the 200 tonne grain storage silos and the Wakely five tonne per hour grain roller mill, which crushes the grain ready for the cows.

“There is a flexible core auger, which feeds the grain through to the individual troughs on the platform, making sure each cow gets the required amount of feed,” says David.

The bagging chute used for preparing feed for calf rearing can be adjusted to suit any type of grain.

The refrigeration system for the new dairy shed was designed and installed by Timaru company Cool Air. Cool Air owner Regan Koster says this is one of his business’ own cost-effective and energy-efficient designs, which can be adapted for any dairy shed.

“We have future-proofed the dairy shed so when the change in legislature comes in, the system has been designed – so the milk will be at the required temperature when it goes into the vat. The quicker the milk is chilled and in the vat, the less likelihood of grades,” says Regan.

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Page 76

TE AWA LAND CO

Coast & Country

Te Awa sticks with tried and tested gear Each farmer’s requirements are slightly different, so Regan likes to discuss the options available within the farmer’s budget and then design the best system to suit.

Cool Air also installed the revolutionary hot water heating system, which re-uses the water used to chill the milk.

It’s recycled into the hot water cylinder, saving water-heating costs. Cool Air provides a full back-up service to all their farming clients.

Automatic yard washing

Dealing with effluent at the source is always more cost-effective than after it is created.

This new dairy shed has a Dungbuster Automatic Yardwashing system installed, which reduces the amount of water used when washing the yard compared to conventional yard washing.

As well, it doesn’t require staff to wash the yard as it’s done automatically, using a fraction of the amount of water.

The scraper moves the solid effluent while the hose jets on the gate wash the liquid away. The yard can be cleaned

before the last lot of cows have finished milking saving time and money.

PPP Industries at Tuakau installed the effluent system and Viking Containment provided the effluent pond liner.

The liner stops the stored effluent leaching into the soil and is contained until Brent is able to irrigate it on to the paddocks.

A and C Gibbs Excavating Limited did all the earthworks for the Schrider’s rotary dairy shed.

“Luckily, we had good weather,” says Alistair Gibbs, who owns A & C Gibbs Excavating Ltd. “It meant we got the job done without any interruptions and building was able to start on time,” says Alistair.

“Brent and Noel knew exactly what they wanted, so we were able to follow their ideas and complete the earthworks as they wanted them.”

Based at Geraldine, A and C Gibbs Excavating Ltd used a scraper and diggers to get the site just right.

They also removed several areas of trees and drained a swamp so the farm lanes could be formed. Alistair says they do mostly rural work, such as dairy conversions in the area and farm and track maintenance.

There are three full-time staff employed at Te Awa Land Company and the new rotary dairy shed can be operated by one person once calving has finished.

The large rectangular yard.

By Helen Wilson

The front of the Te Awa Land Company’s new rotary dairy.

The cow entrance area.

The pit area of the dairy shed.

The cow exit area.

The Protrack system.

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RIVERHOLME PASTURES

Page 78

Coast & Country

A robotic opportunity not to missed

Riverholme Pastures

Farm manager Rhys Grant hoses down the yard.

Alvin and Judith Reid’s new dairy shed at Pleasant Point near Timaru in Canterbury is not quite “milking the cows from the comfort of a warm living room” – but it’s the next best thing.

Sitting comfortably in a large swivel chair in the dairy shed office, with two huge screens and two smaller ones in front of him, Alvin can zoom into any paddock on the farm, the raceway and dairy shed and read the cow’s tag number and see which one is coming in to be milked.

There are several cameras mounted on the roof, which relay images through a computer to the large screens.

“I have always been interested in technology and when I was on the Dexcel board I was involved with the first robotic milking machines at Hamilton, to see if they would work. When converting this dairy farm and building a new dairy shed, I had the chance to install them and see for myself,” says Alvin.

The farm is 132 hectares effective of river flats and has the Opihi and Tengawai rivers on either side. Alvin and Judith had owned the land for 12 years, formerly using it as dairy support for their other dairy farms.

Planning for the dairy conversion started in 2012. It took six months to get “change of land use” approval from Canterbury Regional Council. Once approved, building started and Alvin was able to plan his robotic dairy shed.

Robotic system

During 30 years of dairy farming he’d built up a good relationship with DeLaval and decided to indulge his love of new technology and install their robotic system or Voluntary Milking System – the first DeLaval units in the South Island.

There are six units placed in a circle, rather than a straight line. “To help manage the

system better – think automation, think circles,” says Alvin.

DeLaval district manager Grant Vickers says his company appreciates Alvin’s loyalty to the brand during the years and the DeLaval team was delighted to work on this project with him.

“It took three years to come to fruition and we discussed all the options available.

We designed the complete system including pasture management, which is a three-way voluntary grazing system.”

The cows come in voluntarily over a 24-hour period to be milked.

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RIVERHOLME PASTURES

Second in charge Felicity Hardy checks on one of the Voluntary Milking Systems.

Page 79

A cow being milked in the VMS.

Indulging in love of new technology They are identified by their ear tag and are managed by ‘cow traffic control’ meaning any cows without permission to be milked are denied access and drafted back out to a paddock.

Farm management Grant says if decisions can be it is their time to be milked made from anywhere the cow enters in the world... the VMS, and the hydraulic arm senses the udder, cleans and stimulates the teats ready for milking and then places the cups on each teat.

Once milked out the cups are removed, the teats sprayed and the cow is free to go.

The arms are designed after a human arm and operate quietly and smoothly and are totally reliable.

Parr & Co, of Timaru, business development manager Luke Crabb installed the six robots.

“At the end of the day it is a milking

machine. The installation is to a high standard and the deadlines were met,” says Luke.

True cell counts

The DeLaval Delpro farm management system includes Online Cell Counters which give a true Somatic Cell Count for each cow – meaning it makes decisions before there is a real problem.

The machines are washed a minimum of three times a day and if there is any downtime will be washed again.

The milk line has a four-way milk divert, which separates premium milk from colostrum and antibiotic milk goes where it should. The premium milk goes into the silo at less than six degrees Celsius.

Farm management decisions can be made from anywhere in the world with the Delpro System.

The service agent can use remote access to log in and see what the problem is.

Grant says Parr & Co has five fully-trained technicians just for robotics “as there is a lot of interest in New Zealand and Australia.”.

“The dealers are supported by a 24-hour

technical team of six at DeLaval.”

Owner Cool Air in Timaru Regan Koster installed the refrigeration units at Riverholme Pastures’ new dairy shed – and the builders were Tony Boyce Builders.

Building for robotics

Alvin approached Tony Boyce Builders to build his new robotic dairy shed, one of the few in the area, as they’ve worked with Alvin for about 18 years on other building projects including dairy sheds, farm buildings, concrete platforms and residences.

Alvin and Tim Scott designed the building around the VMS and yard requirements. The building features a viewing platform with large windows overlooking the operation.

The platform is directly accessible via the meeting room from outside.

The building is constructed of a steel frame, polypanel walls and coloursteel roof. The yards included a herringbone pit for a vet area and an effluent weeping wall system was all cast in-situ with a concrete surround.

“We were pleased to be involved with such a forward-thinking client,” says Tony Boyce.

RIVERHOLME PASTURES

Page 80

Zooming in on farm activity

Coast & Country

Riverholme Pastures

Farm owner Alvin Reid, using technology for new dairy shed.

Thompson Precast from Timaru supplied the precast tilt slabs for the dairy shed.

Thompson Precast’s Jason Bray says it was his company’s first involvement in a robotic dairy shed “and we had a tight building frame”.

“The precast tilt slabs are built for longevity and are far easier to keep clean and a lot more durable than block or insulated panel.”

Thompson Precast also provide precast tilt slabs and Y panels for silage and other feed bunkers when a concrete-lined bunker is required rather than an earth-lined one, improving feed quality, reducing contamination and ensuring regulations are complied with.

Feed all the time Rolleston company Permbrand supplied and installed the feed system at Riverholme.

Permbrand sales manager Steve Waters says they supplied the silos and coreless auger system, which is driven by two motors.

“It’s a full loop system, which means the feed bins in the robots are filled with feed all the time. They have a ‘high-low’ sensor in the

robot, so whenever the feed gets below a certain level it will fill automatically.

“The feed acts as an enticement for the cows to come in and be milked. This is the third robotic dairy shed we have been involved with,” says Steve, who says the system is similar to those installed in herringbone dairies “but in this one there are only six droppers, one for each VMR”.

Farm Electric at Winchester sorted the shed’s electrical needs.

“We applied similar electrical methods here as for a rotary dairy shed but made some adaptions to suit a robotic system,” says Farm Electric managing director Kane Rangiawha.

Farm Electric has designed new concepts regarding the hot water systems and dealing with mains pressure.

The electrics are designed so if one part of the dairy shed shuts down due to power failure, the other part will still operate. The team of four electricians also assisted with installing a standby generator.

“I have had a good working relationship with Alvin and Judith over the years and enjoyed

Before

After

working on this dairy shed. It has a robust data network system to withstand the demands of farming innovation in the future,” says Kane.

Earthworks for the new dairy shed was carried out by Blake Downie Contracting of Geraldine. A lot of their work is providing an efficient service for farmers.

Grain-based pellets Compound feed for Riverholme Pastures is sourced through Ashburton-based feed and nutrition company Dairy Business Centre NZ Ltd. The feed pellets are grain-based, high in energy and also contain both macro and trace minerals.

Dairy Business Centre sales manager Will Meads says he keeps in regular contact with Alvin throughout the season to ensure feed is manufactured and delivered on farm in a timely and efficient manner.

Any variables that occur throughout the season, such as an increase or decrease in feed rates are identified early and entered into the company’s delivery calculation spreadsheet and

Parr & Co business development manager Luke Crabb, DeLaval district manager Grant Vickers and farm owners Alvin and Judith Reid. subsequently scheduled in for production and delivery accordingly.

The farm employs two staff; Rhys Grant as farm manager and second in charge is Felicity Hardy.

This new concept in dairy farming is certainly creating a lot of interest – and Alvin reckons it will keep him interested in farming for another 10 years.

His dedication is such that for the first seven weeks of the dairy shed operating, he slept on-site “just to make sure everything was operating correctly”.

“The tech guys have been brilliant to deal with. I just love playing with electronics,” says Alvin, who is a man not afraid to try something new.

“What will be next? Will drones be used?

What productivity gains are to be made by increasing farm automation?” By Helen Wilson

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RIVERHOLME PASTURES

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Page 82

M C LELLAND DAIRIES

Coast & Country

â&#x20AC;&#x2DC;Talkingâ&#x20AC;&#x2122; dairy touts best technology Jason Grantâ&#x20AC;&#x2122;s family has run their 200 hectare Canterbury property for 30 years as a sheep and beef unit â&#x20AC;&#x201C; right up until a few years ago when ďŹ gures told Jason converting to dairy was a no-brainer.

But they also included SmartECR electronic cup removers and SmartSPRAY, which sprays the cowâ&#x20AC;&#x2122;s udders.

SmartSPRAY settings can be customised to spray at the time you choose â&#x20AC;&#x201C; the Grant family has set their system to spray the udder eight seconds after each cow ďŹ nishes milking, while the teat canal is still open.

Dairy entrance with cows in the yard.

â&#x20AC;&#x153;It became clear it was the most economical use for the property, so it was an easy decision,â&#x20AC;? says Jason.

He and wife Anna completed the conversion last year and have just had their ďŹ rst season milking a respectable 800-strong herd.

When building the dairy Jason couldnâ&#x20AC;&#x2122;t go past the package Waikato Milking Systems and their local agents, Timaru Milking Systems, offered him. â&#x20AC;&#x153;Timaru Milking Systems did a really good job with the Waikato plant. Their back-upâ&#x20AC;&#x2122;s been great and the Waikato Milking Systems plantâ&#x20AC;&#x2122;s been going very well,â&#x20AC;? says Jason. â&#x20AC;&#x153;We went with Waikato because itâ&#x20AC;&#x2122;s a simple system while at the same time being really high tech.â&#x20AC;?

Same language

Also on the bail are BailGates with BailMate Rams that not only hold the cow in the bail if sheâ&#x20AC;&#x2122;s kicked the cups off, and needs to go round again, but are linked into LIC Protrackâ&#x20AC;&#x2122;s herd management system.

Waikatoâ&#x20AC;&#x2122;s South Island sales manager Lindsay Giles says the Waikato Milking System talks the same language as Protrackâ&#x20AC;&#x2122;s herd management software â&#x20AC;&#x201C; and the two link using SmartLINK to log a variety of data. â&#x20AC;&#x153;For example, Jason has the SmartD-TECT early mastitis detection system that takes a sample of milk from each quarter at the beginning of milking and tests the conductivity of each of those quarters against the others. â&#x20AC;&#x153;If one quarter is high itâ&#x20AC;&#x2122;s logged to the LIC Protrack computer. If that occurs three consecutive times Protrack sounds an alert when she next enters the bail and the BailGate locks. Then the milker makes the decision to milk her and whether to set Protrackâ&#x20AC;&#x2122;s automatic gate to draft her,â&#x20AC;? says Lindsay.

Off the platform Timaru Milking Systems installed Waikatoâ&#x20AC;&#x2122;s Flomax Milk Pump controlled by a SmartDRIVE milk pump controller and a SmartDRIVE vacuum pump controller â&#x20AC;&#x201C; both are variable speed for serious power saving.

Bails make deal

â&#x20AC;&#x153;I was new to the industry and didnâ&#x20AC;&#x2122;t know a lot about it, so I listened to a lot of advice before making the decision. A big part of it was the bails â&#x20AC;&#x201C; all very uncluttered and user-friendly.â&#x20AC;?

Contract milker Matt Sinton, along with wife Miranda, is also on a learning curve after only four years in dairy after drystock farming. â&#x20AC;&#x153;One of the best things about Waikato Milking Systems is all the electronics are up, out of the way where they canâ&#x20AC;&#x2122;t get wet,â&#x20AC;? says Matt.

As the New Farm Dairies journalist walked into the dairy the LIC Protrack Vantage system voiced there was a â&#x20AC;&#x2DC;smart control errorâ&#x20AC;&#x2122; â&#x20AC;&#x201C; an alert that sounds whenever the plant is switched off.

It was the ďŹ rst experience of a â&#x20AC;&#x2DC;talkingâ&#x20AC;&#x2122; dairy â&#x20AC;&#x201C; and a taster of the technology Jasonâ&#x20AC;&#x2122;s had installed.

On Waikato Milking Systemâ&#x20AC;&#x2122;s 54-bail Orbit rotary platform, Timaru Milking Systems installed mostly standard gear â&#x20AC;&#x201C; like the Waikato 320 Claws and G2 Cluster Washers.

McLelland Dairies

Vet stand

The refrigeration and vat insulation

by Dairycool.

Contract milker Matt Sinton and owner Jason Grant check the herd records.

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Thereâ&#x20AC;&#x2122;s a Milk Recovery System that puts a slug of compressed air through the lines after milking to push out any remaining milk, and a Hush Kit on the air injector for a quieter milking environment.

About the only non-high tech feature is the vet stand Timaru Milking Systems ďŹ xed beside the platform.

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M C LELLAND DAIRIES

Page 83

Converting to dairy a no-brainer Ben’s been fencing in the area for 12 years, and his work pretty much reflects what’s happening in the district.

“About one-third of our work is dairy, one-third is sheep and beef and one-third deer and game parks,” says Ben. “The deer are being pushed up the hill by the dairy, and the sheep are getting pushed further up by the deer,” says Ben.

And still with Protrack, South Island-based company Permbrand 2013 Ltd set up Jason’s in bail feed system.

It has three silos to hold the grain, a grain crushing mill to break it down into meal and augers to carry it between the silos, mill and bail – all controlled by Jason’s Protrack computer.

“It’s a good set up that does the job well,” says Jason.

“We can get individual feeds to the cows with this system, right down to a single cow if we want to – but we haven’t gone that far yet.”

But with a combination of Protrack and dairy feed system specialists Permbrand 2013 in his dairy, he has all the technology available to go pretty much as far he likes.

Swell wells

Recovering heat

Jason’s refrigeration set-up doesn’t lack technology either. Dairycool sales manager Lee Gilbert fixed up the dairy’s refrigeration needs.

“Jason has opted for a Mahana Blue heat recovery system that harvests the heat from the refrigeration unit to get about 200 l per hour of 85 degrees Celsius water,” says Lee. “It’s still generally regarded as the most reliable system on the market.”

The 15hp refrigeration unit that services both milk silos is piped so the refrigeration capacity automatically goes to where it’s needed.

And once the milk is cooled, the silo has an insulating blanket wrapped around it for added efficiency.

New digs

Hub of the platform, from inside the new dairy.

Dairycool sales manager Lee Gilbert, with the Mahana Blue unit.

LIC technician Bin Oy fine-tunes the LIC Protrack system.

“They’re local and I know them personally, so I knew they’d do a good job,” says Jason.

The same applied to local fencer Ben Haugh Fencing. Jason knew Ben well and had no hesitation in getting him to re-fence the property, about 15-16km of new fence.

“We replaced all the fences, except on the boundary. The irrigators changed everything. Ben did an exceptional job getting everything sorted out,” says Jason.

The new dairy needed more staff than the old drystock farm – and with new staff came the need for more accommodation.

So Jason brought in Johnson Building to erect two single quarters and a manager’s house. For this job, like so many others in the rural sector, local knowledge and community ties came to the fore.

Helping turn McLellands Dairies’ vision into reality! waikatomilking.co.nz | 100% NZ Owned & Operated

All Jason’s dairy, house and stock water needs come from a couple of wells drilled by Geraldine-based Barber Well Drilling. Barber’s had to go quite deep through layers of clay to reach the sweet water.

“They had to go down about 70m to get a really good reliable source of clean water. Shallow bores can have a tendency to go a bit dry in the summer,” says Jason.

Once the 150mm-wide hole was drilled, Barber Well Drilling’s team lined it with thick-wall steel casing to prevent any buckling – and it ensures Jason gets as long a life out of his wells as possible.

All pretty simple for Barbers considering they have the capacity to drill straight wells up to 400mm diameter and up to 300m downwards.

For Jason and Anna it’s definitely paid off to go local for his contractors. The result is an excellent job done by people they know and trust – which all adds up to peace of mind not just for them, but for Matt and Miranda as well.

The single quarters built by Johnson Building.

By Graeme Dobson

SAYWELL

Page 84

Coast & Country

Sons get to work in new Geraldine dairy The 54-bail rotary dairy from the yards.

The iFLOW platform installed by Duncan Engineering.

All new tracks by Hobbs & Banks.

Nestled in that little space between the plains and the mountains, John Saywellâ&#x20AC;&#x2122;s 230 hectare Geraldine farm has the best of both worlds â&#x20AC;&#x201C; lush green ďŹ&#x201A;at to rolling country and magniďŹ cent views.

Itâ&#x20AC;&#x2122;s pristine land and John has every intention of keeping it that way â&#x20AC;&#x201C; but he does have a problem with a comparatively high rainfall, a high water table and clay.

In other words much of his land is often wet, so when he decided to build a new dairy it needed a lot of ďŹ ll to build the foundations up.

Fortunately he has an excellent source of a gravel/clay mix on the farm that Paul Smith Earthmoving could use when they did the

Expert earthmoving Paul Smith Earthmoving needed to excavate a very large pit to get the gravel with just the right amount of clay inclusion.

The job took them a month, off and on, because of the weather â&#x20AC;&#x201C; it was unusually wet, which made for difďŹ cult conditions, but certainly nothing Paul couldnâ&#x20AC;&#x2122;t cope with easily.

The result is a new dairy and yard thatâ&#x20AC;&#x2122;s raised high and dry a good metre above the surrounding country and a very large borrow pit â&#x20AC;&#x201C; both Johnâ&#x20AC;&#x2122;s very happy with.

He turned the old pit into a wetland that provides an excellent duck habitat.

Currently, his sons Pete and Tim Saywell

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site-work and foundations for the new 54-bail rotary dairy and yards.

work the farm â&#x20AC;&#x201C; Tim as sharemilker and Pete as farm manager.

When Tim returned from his OE a couple of years ago, he agreed to come back to the farm if John would put in a new dairy.

And somewhat to Timâ&#x20AC;&#x2122;s surprise, John agreed.

So while Paul Smith Earthmoving was doing the site-works, they looked around for a new milking plant.

Easy decision

â&#x20AC;&#x153;Weâ&#x20AC;&#x2122;ve always used GEA Farm Technologies agents Duncan Engineering, and Garyâ&#x20AC;&#x2122;s been pretty good to us,â&#x20AC;? says Tim. â&#x20AC;&#x153;But we shopped around and asked a lot of people and GEA Milfos got all good reports â&#x20AC;&#x201C; easy decision,â&#x20AC;? says Tim. So they opted for GEA Farm Technologies Milfos platform and machines. First GEAâ&#x20AC;&#x2122;s local agents Temuka-based Duncan Engineering fabricated the GEA Milfos FT iFLOW Double I-Beam platform in their Temuka factory.

Brothers on-farm â&#x20AC;&#x201C; farm manager Pete Saywell and sharemilker Tim Saywell, and guard dog Tuffy.

The Double I-Beam refers to the platform rotating on an I-Beam mounted to the top of the plinth and another mounted on nylon rollers under the spokes giving it a â&#x20AC;&#x2DC;truck and trailerâ&#x20AC;&#x2122; action.

With the platform in place Duncan Engineering installed the GEA Farm Technologies milking plant.

GEA Farm Technologies area sales manager Peter Vaughan says John chose the iCONVEYOR machines with the â&#x20AC;&#x2DC;drop downâ&#x20AC;&#x2122; option that directs the cups under the bridge as the platform turns, then lifts them back up at cups-on.

This way thereâ&#x20AC;&#x2122;s no rubberware or clusters that can be tangled by the cows as they enter or exit.

John also opted for iCR Cup Removers, Cow Restraints and iNTELLAB to meter each cowâ&#x20AC;&#x2122;s milk yield, fat, protein, lactose and conductivity, and it sends to the computer.

The whole dairy is a very neat package thatâ&#x20AC;&#x2122;s

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SAYWELL

Page 85

Saywell dairy a power-saving machine Effluent pond.

Saywell The methane-powered generator, set to save the Saywell farm money. integration owes a lot to the fact Duncan Engineering installed pretty much all of it, from the platform and plant through to the refrigeration and plumbing and pumping.

Snap chilling

John stuck with GEA Farm Technologies for his cooling with an iCONVERTER aquaDIRECT, snap chilling technology that uses off-peak power to freeze phase-change nodules in a tank of glycol.

During milking a double-bank plate cooler chills the milk, then the glycol brings it down to four-six degrees Celsius as it enters the vat –very cool and economical.

John is really serious about power-saving and it could be said he’s a leader in the field.

He’s on the mains supply, but eventually the bulk of his power needs will come from a solar array that produces about 15kw and a 50kw bio gas generator run on methane he harvests from his effluent pond.

Selling and saving power

And when the methane plant is fully operational John will be selling power back to the grid.

GEA Milfos iCONVERTER glycol unit.

Ashburton-based Electraserve’s general manager Blair Watson says they set up John’s entire multi-source power system – from bringing in the mains to setting up and integrating all the electricity sources and reticulating it where-ever it’s needed throughout the farm.

John’s even planning on installing a large diesel generator— so he’s never going to suffer from a power cut.

“Our next step is to rig up a monitoring system that will enable John to monitor his power production and use from his computer,” says Blair.

Then Aspect Environmental Lining supplied and fitted a Geomembrane liner over the top of the pond to create a closed container for the effluent.

It’s just like a very large septic tank, but instead of gases being vented to the atmosphere, they’re put to good use.

Trapped gas is piped under controlled conditions to a scrubber where water and impurities

Fonterra farm supply number and AEL pond liner sign.

are removed, then onto a specially adapted generator.

Safe wrangling

It’s not just power that’s economised on this farm. Out in the yard is one of the more innovative labour-saving devices you’re ever likely to find on a farm – The Wrangler.

Not only is The Wrangler a labour-saving device, it’s actually a safety device that allows cows to be immobilised so the vet or farmer can work on them without fear of being kicked or trodden on.

It’s especially helpful for working on hooves, as it allows each leg to be lifted and immobilised independently.

The Wrangler is an excellent piece of good Kiwi ingenuity, and one that doesn’t use an amp of John’s home-grown electricity or need any computer power at all.

Hobbs & Banks laid the raceways across the farm to service the new dairy. The farm was

reconfigured into a ‘pie shape’ to cater for the radial irrigation system with tracks radiating from the dairy to a circular track around the outside.

Hobbs & Banks director Peter Hobbs says he came into contact with John soon after he bought the farm in the 1990s.

“It was all open drains and pretty waterlogged then,” says Peter.

“We went in and during time closed over most of the drains and got it looking much better. “When the new dairy went in we renewed between 70-80 per cent of John’s raceways with Maungati limestone, which is much harder than other limestones so it lasts longer and is easier to clean.”

Between the clean white tracks and the new dairy, the farm looks superb – and the backdrop of the Southern Alps doesn’t do any harm either.

By Graeme Dobson

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JANSON AG

Page 86

Coast & Country

Giving up grazing, Garth’s goals switch to dairy

By Graeme Dobson

Garth Janson is so impressed with his new Chapman Dairy, he’s booked another one exactly the same for next season.

dairy. They’ll increase the herd to 1400 during the next two-three years as everything settles down and they get their full water allocation from the irrigation scheme.

Like most Canterbury dairies, Garth’s new Chapman Dairy delivers dairy had to be located under the central Their dairy is a Chapman Dairy irrigation pivot – which put it right in the design, built by Nigel Hodges, owner middle of his new 325ha conversion and at of Rural Building Solutions, and is just end of a hell of a long tanker track. one of the many of the Chapman Dairy But this was just a small sacridesigns springing up around the country. fice to make in the interests Chapman Dairy designs are distinctive, The Donald Slot of efficiency. particularly with their trademark veranda in action.

Garth bought the land and vented roof.

10 years ago and used it But the design is flexible and it’s up to the for dairy grazing until he farmer what he wants – even the veranda and vents are completed the converoptional – but in Nigel’s experience no-one has yet opted sion last year. not to have them.

Garth, his farm manThat’s probably because the veranda provides that extra bit ager Alan Dalziel and of protection from the weather and with the roof vents gives sharemilker Andrew Horn very good air circulation. have just completed their Cups are thoroughly The Chapman Dairy also has excellent natural lighting from first season with an 800-strong washed just before cupsthe fairly extravagant clear plastic panels incorporated into the herd at the new 80-bail rotary on. roof and ample windows around the platform area.

Light, air and protection from the weather – what else could a farmer want? Unless it’s the comfortable staff room and facilities with sliding glass door access and all aluminium joinery Chapman Dairies has built into an otherwise very functional building.

Nigel is one of the builders throughout NZ who is licensed to build Chapman Dairies. This partnership is one of the reasons Garth went to him in the first place.

“He’s got that connection, so there is a substantial organisation behind him. If Nigel fell under a bus or something, someone would come down and fill the gap.

“From an owner’s point of view that connection is pretty important,” says Garth.

Co-operative and helpful

But the Chapman Dairy connection isn’t the only reason Garth went to Nigel.

“My sharemilker Andrew’s been milking since he was knee high, so Andrew and his business partner Luke Campbell and I toured around and looked at a lot of sheds – and in our opinion, Nigel’s stood out.

“So when we sat down with him we liked what we saw and heard – he’s very co-operative and helpful, and that’s been the case all the way through.

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JANSON AG

PH 07 578 0030

Page 87

Blockwork by Advanced Brick & Block, and Acraflex paintwork by Bruce Cameron from Specialised Coatings.

The farm dog – a dying breed.

Stuart Pegg and Philip Read, both from Read Industrial, at the new dairy with a Read Milking System.

One successful build leads to another able and does a good job. We tend to paint a bit more “Andrew and Luke tweaked the plans a bit, but nothing than most dairy builders – and Bruce gives me was a problem and we finished up with a product the total finish I expect.” we’re really pleased with,” says Garth.

And there is certainly a lot of painting For Nigel, that’s the outcome he aims for at Garth’s dairy – as well as the usual every time. sealing coat on the pit walls, there is a “We start with helping the farmer sealing coat of Specialised Coating’s determine where his building should Acraflex to all the block walls. go and the site layout; we listen to his Nigel knows good tradesmen ideas and build what he wants. when he meets them, so he got “This makes each dairy slightly difDuncan Hedgecock’s crew from ferent and it keeps us on our toes,” Advanced Brick & Block lay the says Nigel.

1800 blocks needed on Garth’s job.

“We do a draft layout, then a full As with most of his subcontracstructural design and take care of tors, Nigel’s relationship with the building consents. We projectDuncan is so good he has him on all manage the build as well while we’re his jobs. on-site, but we don’t charge for that. We Farm manager Alan Dalziel, “We do about eight sheds a year with provide most of the tradesmen and get owner Garth Janson and them. They’re not the cheapest, but they paid through knowing they’re going to turn sharemilker Andrew Hoare in respect that it’s a million-dollar-plus dairy up when they’re needed.” their new workplace. so they lay their blocks like it’s a million-dollar house,” says Nigel.

Pleasing painting He finds blocks give him more flexibility than pre-cast One of the tradesmen Nigel organised is North Island-based concrete – and with about 30-block layers, Advanced Brick & painter Bruce Cameron.

Bruce paints all Chapman Dairy builds and flew down specifi- Block can push a quality job through for him in only two-three days. cally for Garth’s job.

The same applies to Nigel’s roofers, Graham Hill Roofing.

“Bruce is about the same price as the local guys, and he’s reli-

Supreme Winner 2013

Lincoln Field Days Agriculture Innovation Award

“We use them on all of our jobs for two reasons,” says Nigel.

“They have the experience – they did the Forsyth Bar in Dunedin – and the staff to be able to put a team in when it’s needed.

“And they do it right and with good attention to the health and safety aspects, which is very important to us.”

With the building up and roofed, Donald Engineering installed the 80-bail platform fabricated in their nearby Edendale factory. Donald Engineering know their stuff. Founder Colin Donald started the company about 35 years ago and has been developing them ever since.

He now sells his platforms directly to farmers in the South Island and via franchises throughout the North Island.

Donald slot

The efficient simplicity of the Donald platform is amply demonstrated by one of the several features they’ve incorporated – it’s called the ‘Donald slot’ and is designed to hold the rubberware safely out of the way when a cow is not milking.

In the dairy business Donald Engineering frequently work hand-in-hand with Rangiora-based milking machine manufacturers Read Industrial Ltd to offer the farmer the complete package, so it was logical a Read Milking Machine was installed.

Read Industrial Ltd’s sales manager Philip Read, who is part of the fourth generation of the family business, the installation process was easy.

Page 88

JANSON AG

Coast & Country

Good crews and cooperation create masterpiece “Once Garth decided on the machinery he wanted and the Donald Engineering boys had finished the platform, we came in and installed the milking machines.

“The thing that’s been good with our company during the years is we’ve stuck with proven technologies – like a very reliable pulsation and wash system.

“That’s what the farmers like – once you put it in, it’s in to stay and there’s not a lot of maintenance or service requirements,” says Philip.

Dairycool sales manager Lee Gilbert says his company prides itself on coming up with options for whatever its clients want to achieve.

“Garth’s got very cold ground water so a conventional refrigeration system can handle his needs for now, and it helped contain his costs.

“But we may have to come back and retrofit a chilled water or glycol unit when the new regulations come in requiring milk going into the vat to be down to 10 degree Celsius.”

sorted Garth and Andrew turned their attention to other aspects of the dairy operation.

They wanted a reliable in-bail feed system, so they went to another local company – Rolleston-based meal feeding specialists Permbrand 2013 Ltd. It’s the first time Garth and Andrew have dealt with Permbrand and they’re very happy with the experience.

“They’ve done the silos, augers, crusher mills, everything to bring the meal feed to the bail,” says Andrew. “Excellent work and top rate equipment.”

That’s probably due, at least in part, to Permbrand using Dairycool sales manBasic system wins No-fault wiring only the world’s best quality feed equipment and components ager Lee Gilbert, with Read Industrial produces a basic system For the all-important electrical wiring they import from Europe and America.

Dairycool’s refrigera– ‘to get the milk from the cow to the silo’ as Garth went for tried and trusted Permbrand may be a local firm for Garth, but they Phil put it – with cup removers the only electrontion unit. when he employed local Leeston firm Promax Plastics’ actually supply, install, service and maintain their ics they’ll incorporate if the client wants.

Nairn Electrical. water tanks. products nationwide.

Other companies can fit any automation to the Read plant “We use them for everything,” says – but if anything goes awry with their computers, the Read Garth. “And the care they took with Water storage solution Milking System will keep milking. Garth and Andrew stuck the job was excellent; I couldn’t fault With limited supply, water storage is an with just the Read Industrial machinery. “There’s less to go them.” especially important issue for Garth and wrong and nothing to break down,” says Andrew.

Nigel shares his opinion, which is Andrew.

Instead of electronics they employ three milkers – two at cupswhy Nairn is on about 60 per cent of To ensure they have adequate water on on, one at cups-off. his jobs. hand they’ve installed five of Promax In the same vein, Garth opted for a basic but high quality With the building, electrics, platform, Plastics’ 33,000 litre tanks. refrigeration system from Dairycool. milking machinery and refrigeration Permbrand feed silos.

Read Industrial’s milk filters.

Cows wait patiently under the central pivot.

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JANSON AG

PH 07 578 0030

Page 89

Dairy marks Canterbury conversion success The new Chapman Dairy at Garth Janson’s Canterbury farm.

Effluent system flows

Calf sheds galore

And it’s not just the cows that are nicely catered for on the new farm. The calves also have nice new accommodation courtesy of Darfield ITM. Darfield ITM operations manager Steve Borrie says they supplied kitsets to Garth for three open-bay calf sheds – a three-bay, a six-bay and seven-bay.

“We supply all sorts of timber farm buildings, from small shelters up to the biggest barns.

“All our buildings are designed and priced according to the intended site because each site has specific configurations, such as snow or wind loading,” says Steve.

“We supply everything from kit-sets like Garth’s, up to the complete build, including consents.”

The settlement pond with an IS Dam Lining Ltd pond liner.

on commercial work in Christchurch.

When he started on his own in the dairy-building business Nigel soon realised he needed a reliable, professional drainlayer to get the quality job he wanted.

“I needed someone with a professional approach. Dean has that, so I persuaded him into the dairy industry,” says Nigel.

“He’s proved very good to work with and always does a good, professional job.”

Drainlaying is an important part of any dairy build and Nigel has just the man for the job – Dean Wilke from Dean’s Drainage Contracting.

Dean subcontracts directly to Nigel and works on most of his jobs.

They first met when Nigel was a foreman

And a vital one – it’s Dean’s drains that take effluent away from the dairy and into the effluent system.

The effluent flows from the dairy through a stone trap and into an IS Dam Lining Ltd lined 1500m3 and 1.5 million litre settlement pond.

There a crust forms over the top and the solids settle out.

Then the green water from beneath the crust flows through a pipe into a 1500m3 storage pond, with 1.5 million litre capacity, that’s also lined by IS Dam Lining – all without any electrical or mechanical components.

Dean’s Drainage Contracting connected the effluent ponds to the dairy and IS Dam Lining and fitted the all-important HDPE plastic liner into the effluent ponds to ensure they comply with all environmental regulations, especially the need for adequate effluent storage on farms.

“IS Dam Lining was a very good crew. The boys worked really hard and they did a very professional job,” says Andrew.

And that comment sums up the whole job – good crews, cooperation and professionalism, inevitably resulting in a top grade dairy.

By Graeme Dobson

Green water effluent pond with an Irrigation Services’ pond liner

DONALD engineering

LTD

Promax offered Garth a choice from their range of top quality water storage options – all one-piece corrugated plastic manufactured for maximum strength.

The plastic material allows the tanks to be made in a choice of 14 colours to ensure they blend into any dairy’s environment, a commendable attention to aesthetic detail.

Such attention to detail comes from the years of research and development Promax has put into every one of their products, allowing them to back Rural Building Solutions their tanks with a 10-year warranty, owner Nigel Hodges at and an impressive 20 years on their the rotary dairy he built larger BT range. for Garth Janson.

Page 90

NETHERLAND HOLDINGS

Coast & Country

Attractive, modern, easy - she’s a beauty Roel and Diana Wobben’s 2IC Kelly Holland is really happy with the working conditions her employers have provided for her – they even had Dairycool install a heat pump in the staff room.

Roel built the new 60-bail rotary dairy at his Eyreton farm in Canterbury to reduce the distance 500 of his 1700 cows have to walk each day.

The 420 hectare farm has another 80-bail dairy for the other 1200 cows, but the whole system is kept fluid.

“The new dairy is a one-person operation that takes just one hour in the afternoon and about two hours in the morning,” says Kelly. “It’s a really great dairy to work in – it’s all so modern and very easy to keep clean.

The Chapman Dairy design has excellent natural lighting.

Milfos clusters and cup removers.

Attractive

And it’s attractive too. It’s unusual to find a dairy, especially a brand new one, with professional landscaping around it – but that’s what Roel and Diana have done.

They called Farmscapes Rural Landscapes to contour the churned up ground into banks and then plant an array of easy care native plants.

These will not only look very attractive when they mature, they’ll also act as an effective windbreak and give protection from the frequent cold winds that blow through this part of the country.

This is typical of Roel and Diana’s forward thinking – but as this is their third new dairy they do have the experience behind them to know what they want.

And what they want is the best and most energy efficient dairy on the market, which is why they chose a Chapman Dairy design with a 60-bail rotary platform fitted with GEA Milfos milking machines and a GEA Farm Technologies Houle flood wash system.

Roel had seen quite a few Chapman Dairy-designed buildings around the area and he liked what he saw.

The bee’s knees

He also liked the standard of work he saw from Chapman Dairy licensed builder Nigel Hodges’ Rural Building Solutions.

The Chapman Dairy-designed shed from the yards.

“I’d seen a lot of Nigel’s work – and, frankly, it’s the bee’s knees,” says Roel. “His service is excellent and the job was on time.”

Actually it was a two-part job: the dairy itself and a huge 102m by 41m – about 4200m2 – feed pad.

It took Nigel four months to complete the job with two teams; one working on the dairy building and another on the yards and effluent system.

And it wasn’t just the employees getting their hands dirty, as a hands-on boss Nigel screeded about one third of the yard himself.

“There’s nothing better for quality control

– besides, we needed everyone for this one,” says Nigel.

He normally brings his own subcontractors onto the site so he can more efficiently manage the project, but in this case Roel insisted on using Christchurch Readymix to supply the concrete.

Impressive service

Nigel hadn’t used Christchurch Readymix before, but as Roel had a good relationship with them he was happy to agree.

“They impressed us hugely with their service as well as the quality and consistency of their

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Netherland Holdings concrete, which was fantastic,” says Nigel.

“Their mix design and raw materials are absolutely fantastic to work with.”

Altogether Christchurch Readymix supplied 470m3 concrete in the feed pad – that’s roughly 100 trucks – plus another couple of hundred metres in the dairy.

In a yard this size there’s not just a lot of concrete, there’s also a lot of rails and gates – and Roel had them covered as well.

Grant Forrest from Forrest Engineering sorted out this component because Roel knew him and trusted him to do the quality job he expected – and Nigel wasn’t let down.

PH 07 578 0030

NETHERLAND HOLDINGS

Page 91

Caring farm owners look after staff and cows

The Permbrand 2013 installed feed system.

Nairn Electrical brought the power in for the GEA Milfos milking machines.

Bruce Cameron’s Acraflex paint-job, with their sign.

“Advanced Brick & Block always do respect a job and take a lot of care with it; and they always get it done on time.”

All those blocks needed sealing – and that’s where North Island-based painter Bruce Cameron came in.

Bruce travels around the country to paint Chapman Dairy-designed sheds with Specialised Coating’s Acraflex, a product specifically developed for its sealing and protecting qualities.

As well as being very functional, Acraflex looks pretty good and brightens up any dairy – an important consideration with this much painting.

For the dairy’s roofing Nigel used another of his regular stable of subcontractors, Graham Hill Roofing.

“We regularly check their price and they’ve always come in cheaper than the competition. They’ve got the staff and the experience to do a bloody good job and provide us with a really good service,” says Nigel.

Combo that works

Farmscapes Rural Landscapes’ landscaping makes the dairy an attractive workplace.

“I’d heard about Grant but hadn’t had the opportunity to work with him before,” says Nigel.

“He turned out to be very good to work with and has done an excellent job.”

But before any concrete could be laid or steel-work fabricated, the site had to be prepared.

For this they needed Alex Mason Contracting Ltd and Mitchelmore Contracting Ltd. The initial stripping and site work was done by Alex Mason, then Ross Mitchelmore came after him to finish the yard work and prepare the dairy site ready for the builder.

“Alex came in and stripped all this and got it ready, dug the pond and piled the shingle to either side,” says Ross.

“Then we supplied the top-up shingle from the river crossings and prepared it all ready for concrete. We also dug the hole for the centre of the platform.”

Ross also did all the other bits and pieces of earthworks needed, including supplying shingle to top off the tracks around the farm.

Solid block-work

For the most part Nigel used his own highly experienced builders and regular

subcontractors.

One of these is blocklayer Duncan Hedgecock, from Advanced Brick & Block.

Nigel has a preference for block-work wherever possible on his jobs – it gives him more flexibility –and on a job this size there was bound to be a lot of work for the brickies.

Duncan and the Advanced Brick & Block crew have proved themselves so reliable in the past that they now do all Nigel’s work.

“This job was pretty extensive, especially with the big stone trap and reception pit, as well as everything in the dairy itself, but there were no problems,” says Nigel.

With the building waterproofed the local GEA Milfos agents moved in. Duncan Engineering installed the GEA Milfos 60-bail iFLOW platform with Stocker Dairy Services fitting the iCONVEYER milking machines, iCR Cup Removers and cow restraints.

Stocker also installed the GEA Milfos iNTELSCAN Milk Meters to help with the herd management.

GEA Area Sales Manager for South Canterbury/ North Otago/West Coast Peter Vaughan says: “This combination accounts for more than 90 per cent of what we sell in this area”.

Roel had absolutely no hesitation in selecting all GEA Milfos milking plant and Stocker Dairy Services to install it.

“I’ve always had Milfos and found them very reliable, and Stocker’s service can’t be bettered,” he says.

Reliable refrigeration is an important adjunct to the milking system, so Roel had Dairycool install his refrigeration complete with a Mahana Blue heat recovery system and a silo insulation wrap.

NETHERLAND HOLDINGS

Page 92

Coast & Country

New dairy at Eyreton sells itself Dairycool’s sales manager Lee Gilbert says this is a pretty standard system. “There’s no need for snap chillers because the ground water here is so cold.”

The GEA Milfos dairy control centre.

Caring for all

As a caring boss Roel also had Dairycool fit a heat pump in the staff room – and as a caring farmer, he had Rolleston based meal feed specialists Permbrand 2013 Ltd install an in-bail feed system using some of the world’s best quality storage silos, crusher mills and augers.

Roel also brought the electricians, Nairn Electrical, onto the job – but this time it was someone Nigel knew well.

Nairn Electrical are on about 60 per cent of Nigel’s jobs – and he’s probably the best recommendation they could wish for.

GEA Technologies didn’t stop in the dairy – they’ve also had a major input into the feed-pad where they installed new GEA Houle flush valves to flood wash the waste from the whole feed-pad.

And the innovation attracted about 70 farmers to an open day at Roel’s dairy. Why such interest?

The GEA Houle system recycles water so efficiently it can reduce fresh water usage in the dairy by up to 70 per cent – a very important consideration when councils are continuing to tighten water allocations, and in some areas giving specific allocations to farms and dairies separately.

In Roel’s case the miserly GEA Houle system allows him to use just 12,000 litres per day – about what he’d normally use for a herd half his size.

“The wash carries effluent down a 1.5 degree slope through a large, drive-in stone trap and into a ‘reception pit’.

From there an Agi-pump agitates and pumps the raw effluent over a 2.5m by 2.5 m slope screen that separates the solids before the liquid gravity-feeds to the pond – all with no moving parts.

“The solids drop off the screen into a bunker to be spread onto the pastures,” says Peter.

Nigel Hodges from Rural Building Solutions, with his feed pad in operation.

Background: The green water pond that Alex Mason Contracting Ltd dug.

Netherland Holdings The green water is pumped back to the Houle flush valves by a high volume transfer pump – at 8000 litres per minute – to begin the whole process again.

Feed pad fancy

And for Nigel, the feed-pad was an interesting challenge. “The yard slope is critical for an efficient wash,” he says.

“But this was one of the best-prepared sites we’ve had and that let the boys be pretty accurate with the box work.

“Each box needed a fall of 46-47 mm over

The GEA Houle Flush Valves flood-wash takes the effluent into a drive-in stone trap and into a reception pit where an Agi-pump agitates it and pumps it on to a slopescreen. sional approach to his work, so I lured Dean 3m and we ended up with 14.911 mm per metre over 102m, as close to the ideal 16mm across.”

Nigel has developed a bit of a liking for per metre as you’re likely to get,” says Nigel, feed pads after this job – he seems to like the justifiably proud. way they complete the overall dairy package Dean Wilke from Dean’s Drainage Con– and from the look of this job, he’ll get his tracting is another of Nigel’s direct subbies fill of them. and works on most of his jobs.

And this dairy is already selling itself. A “Dean’s a commercial drainlayer from farmer Roel knows came to have a look at Christchurch that I’d dealt with in my days as the new shed and said: “Plant, platform, a commercial building foreman,” says Nigel. layout, site work, feed pad. Yep, just build “When I started out in this business I had me this – exactly the same”. mixed results with other drainlayers and

By Graeme Dobson wanted someone who brought a profes-

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Page 93

GSB FARMS

Page 94

Coast & Country

GSB Farms But heâ&#x20AC;&#x2122;s never seen a dairy like this before.

Sixteen years ago he came to New Zealand for a year on his OE and stayed permanently, working on farms in the North Island.

Now heâ&#x20AC;&#x2122;s in Canterbury managing Graham and Shelley Wallâ&#x20AC;&#x2122;s new 200 hectares, plus

By Graeme Dobson 120ha run-off, conversion.

The new 80-bail Waikato Platform with WMS clusters, cup removers Milking Systemsâ&#x20AC;&#x2122; rotary dairy and retaining arms. was completed last September, ready to milk 750 cows in two herds this season.

Waikato Milking Systemsâ&#x20AC;&#x2122; South Island sales manager Lindsay Giles says this is an elite Orbit concrete rotary platform, made in Waikatoâ&#x20AC;&#x2122;s Hamilton plant.

Itâ&#x20AC;&#x2122;s been ďŹ tted by Ashburton Milking Systems with standard Waikato 320 Claws and G2

Richard Ellison was brought up on a dairy farm in the UK â&#x20AC;&#x201C; and as he puts it: has been â&#x20AC;&#x153;milking cows, man and boyâ&#x20AC;? all his life.

Sustainable Waterâ&#x20AC;&#x2122;s efďŹ&#x201A;uent pond liner.

cluster washers, SmartECRs (electronic cup removers) and BailGates with BailMate Rams.

After the SmartECR takes the cups off teat, sanitation is taken care of by a SmartSPRAY automatic teat spray system complete with leg spreaders.

The machinery includes of two Fristam milk pumps and two SmartPULS digital pulsation systems â&#x20AC;&#x201C; on a platform this size they need two â&#x20AC;&#x201C; controlled by SmartDRIVE variable speed milk pump controllers.

The BP500 blower vacuum pump is also controlled by a variable speed device â&#x20AC;&#x201C; an 18kw SmartDRIVE vacuum pump controller, giving the Waikato Milking Machine some serious power-saving capacity.

Milking is made easy for the farmer by the central wireless controller that controls the milking plant â&#x20AC;&#x201C; all Richard has to do is press one button to set all the machines to â&#x20AC;&#x2DC;milkâ&#x20AC;&#x2122;.

When milking is ďŹ nished WMSâ&#x20AC;&#x2122; Milk

The massive Simple Sheltersâ&#x20AC;&#x2122; cow shelter.

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Obvious choice

Ashburton-based Gavin Young Electrical handled most of the wiring for the conversion.

Gavin did all of Graham and Shelleyâ&#x20AC;&#x2122;s electrical work on their previous farm, so he was the obvious choice for the new conversion, And as the old saying goes: â&#x20AC;&#x2DC;When youâ&#x20AC;&#x2122;ve got a good tradie, stick with himâ&#x20AC;&#x2122;. â&#x20AC;&#x153;He wired up pretty much all the new dairy and houses; everything for the conversion except the The Waikato Milking Systems big irrigators and pumps,â&#x20AC;?

SmartSPRAY automatic teat spray. says Richard.

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Recovery System puts a slug of compressed air through the lines to push the last of the milk into the vat.

Then all Richard needs to do is push another button and Waikatoâ&#x20AC;&#x2122;s SmartWASH, a pre-programmed wash controller, takes over. â&#x20AC;&#x153;The farmer gets on with other work while SmartWASH disperses the water, detergent and runs the wash. Then it turns everything off, so thereâ&#x20AC;&#x2122;s no need to wait around,â&#x20AC;? says Lindsay. â&#x20AC;&#x153;And thereâ&#x20AC;&#x2122;s no need to stop the platform to wash or purge because it all goes through a â&#x20AC;&#x2DC;three-port wash glandâ&#x20AC;&#x2122; in the central hub, so if needed it can be done quickly between herds.â&#x20AC;?

It all adds up to an efďŹ cient operation â&#x20AC;&#x201C; and quick, usually cups-on at 5am and Richard is out by 6.30am.

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PH 07 578 0030

Page 95

Canterbury conversion gets 80-bail rotary He didnâ&#x20AC;&#x2122;t have any work with Waikato Milking Systemâ&#x20AC;&#x2122;s vet platform either â&#x20AC;&#x201C; itâ&#x20AC;&#x2122;s about the only thing Ashburton Milking Systems put into the dairy thatâ&#x20AC;&#x2122;s not high technology.

Normally held upright out of the way, the platform is lowered manually when needed to give a solid work place with easy access to the cows. Itâ&#x20AC;&#x2122;s designed with reliability, practicality, ease of use and safety in mind.

World leaders

Tru-Testâ&#x20AC;&#x2122;s DTS Milk Cooling Solutionsâ&#x20AC;&#x2122; 18hp Patton Pak refrigeration unit with a heat recovery unit provides the dairyâ&#x20AC;&#x2122;s refrigeration.

DTS has recently joined the Tru-Test Group, making them part of one of the worldâ&#x20AC;&#x2122;s leaders in farm technology and ensuring clients like Graham and Shelley have the best technology.

Tru-Testâ&#x20AC;&#x2122;s DTS area sales manager for Westland, Jamie Boswell, says the heat recovery system is a major saving in power. â&#x20AC;&#x153;It puts water into the hot water cylinders at about 50 degrees Celsius, which is a lot better than heating water from cold.â&#x20AC;?

And Canterbury ground water is very cold, which is a bonus for refrigeration as thereâ&#x20AC;&#x2122;s no need to pre-chill the water for the plate cooler.

a predetermined mix of crushed grains and minerals to feed bins in each bail. â&#x20AC;&#x153;Permbrand 2013 Ltd supplied and installed all the feed system, including the bins, augers, hoppers and grain crusher mills â&#x20AC;&#x201C; all the hardware,â&#x20AC;? says Richard.

Kiwi invention

Outside the cows get their feed supplements in a NZ-developed and manufactured Simple Shelter 20m by 140m shelter.

The structure, which comfortably houses 350 cows, is an open-ended, opaque Tuffspan Membrane roofed modular tunnel design that provides excellent natural lighting and ventilation.

The clearspan construction provides easy access for machinery â&#x20AC;&#x201C; and more importantly where stock are being fed, no roosts for birds.

And it gives good protection from bad weather. Richard says that with the correct orientation and shelter from tree lines it stays ďŹ ve-10 degrees Celsius warmer inside than out â&#x20AC;&#x201C; even during a howling southerly. And in summer itâ&#x20AC;&#x2122;s a good three degrees Celsius cooler inside.

Simple Shelter sales consultant Harvey Cottle says their structures are a NZ invention, engineered and

manufactured in Auckland to stand up to pretty much anything the elements throw at them â&#x20AC;&#x201C; including Canterbury gales.

Graham and Shelleyâ&#x20AC;&#x2122;s shelter has only just been ďŹ nished, but itâ&#x20AC;&#x2122;s already proving its worth. â&#x20AC;&#x153;Two weeks ago we had some consistent heavy rain, so I brought one herd in here during the day and the other overnight. â&#x20AC;&#x153;That halved the pugging on the farm, improved feed utilisation and minimised our drop in production compared with our neighbours,â&#x20AC;? says Richard. â&#x20AC;&#x153;Weâ&#x20AC;&#x2122;re also looking at bringing our springers in here; that will make it much easier to keep an eye on them, but ultimately the weather will determine just how much we use the shelter.â&#x20AC;?

Stone trap

The new efďŹ&#x201A;uent system is fairly standard â&#x20AC;&#x201C; a stone trap followed by a clay-lined settlement pond connected by a pipe. It is laid about half a metre below the surface, to a plastic-lined green water pond; then pumped onto the paddocks via the irrigator pivots.

Sustainable Water owner/director Tim Oâ&#x20AC;&#x2122;Sullivan says they installed a high density polyethylene pond liner in the 3000m3 green water pond. â&#x20AC;&#x153;Filtered efďŹ&#x201A;uent goes into the settlement

pond where the solids sink to the bottom, a hard crust forms on top and the liquids ďŹ&#x201A;ow through to the second pond,â&#x20AC;? says Richard. â&#x20AC;&#x153;Exactly like a large, open septic tank.â&#x20AC;?

A major safety feature of the efďŹ&#x201A;uent ponds is the secure fencing around them.

This was done by Andrew Morgan from Morgan Fencing, which did all the major new fencing work on the conversion.

The place was fenced as a run-off, so some fences needed to be realigned with tracks and the major new lane-way down the middle of the farm.

The whole operation appears to have come together very nicely â&#x20AC;&#x201C; and itâ&#x20AC;&#x2122;s all got one Englishman very excited about his future

By Graeme Dobson in dairy farming.

The three-port wash gland in the central hub.

Meal made easy

On-platform each cow gets an individually formulated meal mix provided by dairy meal-feed specialists Permbrand 2013 Ltdâ&#x20AC;&#x2122;s feed system that delivers meal directly to the bails.

Permbrandâ&#x20AC;&#x2122;s augers work with the dairyâ&#x20AC;&#x2122;s computer to deliver

Waikato Milking Systemsâ&#x20AC;&#x2122; South Island sales manager Lindsay Giles and farm manager Richard Ellison at Waikatoâ&#x20AC;&#x2122;s WiďŹ controls.

Tru Testâ&#x20AC;&#x2122;s DTS Milk Cooling Solutionsâ&#x20AC;&#x2122; 18hp Patton Pak refrigeration unit.

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Page 96

Coast & Country

A clever Canterbury conversion Putting a rotary platform on his 175 hectare new dairy conversion just out of Hinds in south Canterbury was a marginal call for Chris Boldeston.

The platform waiting for the concrete.

But once he’d opted for the 54-bail rotary he went for the best technology available – which meant a Milfos Dairy from GEA Farm Technologies.

In fact, Chris opted for such advanced features that his dairy is a showpiece for the new GEA Milfos FT iCORE milking plant, with their new bails the first in the South Island.

But unfortunately job completion suffered a little “unavoidable slippage” caused by changes around the building consent process and other dairies were completed with the new technology before his.

It’s a hassle, but this is Chris’s second dairy conversion in the area – the first was in 1984 – so he knows the processes and the pitfalls.

“The new completion date is August, just in time for calving so it doesn’t really matter,” says Chris.

Accommodating ideas

The final pour for the yard was due the following day.

With 650 cows due to calve it will be tight, but his builder Greg Sim, from Greg Sim Builders Ltd, is confident.

Chris has had a long presence in the area and when it comes to employing his contractors he tries to employ locally – and Greg is a local Chris is well acquainted with and has employed many times. He’d always found him to be a man who’s happy to accommodate his clients.

“We build whatever people want. We’re flexible; we don’t have a set plan that says ‘that’s what you’ve got to have’,” says Greg.

“I put a plan in front of the client and say that that’s what you have, but if you want to change it we can change.

“Chris had a few ideas he wanted incorpo-

rated, like the gutter up the middle of the yard and steel instead of wooden purlins, but it’s all pretty straightforward,” says Greg.

“I always work on the theory that if you leave a good job behind you, it will sell itself.”

Greg builds from ‘green field’ and does everything from the site-works through to handover.

“We go in and lay it all out, discuss it all with the cocky to get the cow flow right, then do the site work – all the building, our own panelling, put all our own roofs on and all our own concrete.

“We’d do 90 per cent of the work,” says Greg.

Chris under the circumstances, Simbo, as he calls Greg, has done an outstanding job. “He’s built quite a few dairies around the area, so he knows what he’s doing,” says Chris.

Actually, Greg and Chris have had a long and fruitful relationship and apart from buildings Greg’s done a lot of work on Chris’ properties, including shifting trees out of the radial irrigator’s path.

“Chris likes his trees,” says Greg. “Some of the trees we’ve shifted twice – that’s big ones.

“We’ve got an excellent operator, Jock Moore, and four diggers that are very handy for the job. For the big jobs, like standing the shelterbelts up again after blows, Chris’ son Josh works another of my machines alongside Jock.”

It’s a nice change, from seeing most farmers knock them over.

Clever control Once the building was ready, Ashburton-based GEA agents, Stocker Dairy Services, installed a GEA Milfos Farm Technologies milking system.

GEA FT’s area sales manager Peter Vaughan says Stockers fitted Chris’ dairy with the new GEN2 Bails on the GEA Milfos iFLOW platform and iCONVEYER machines.

There will also be ICR Cup Removers and Cow Restraints controlled by GEA FT’s new iCORE system – one of the first dairies to have them.

CIB

PH 07 578 0030

Page 97

Advanced features make dairy showpiece The iCORE is a very clever, one-button control system that can be configured to give individual pulsation control at each milking point and provides conductivity-based intelligent cup removal using a TLS Smart Ram. Incorporated in the cup removers is a ‘kick off ’ sensor that shuts off the vacuum to the cluster and tells the Cow Restraints to keep the miscreant in the bail for another round.

Linked into iCORE will be the GEA FT iPUD4000 Post Spray In-Bail Teat Sprayer – for excellent teat coverage with minimum chemicals – and a Heads Down Display.

The HDD is a platform mounted leg-spreader fitted with an illuminated panel that displays a range of information on the cow where it’s easy for the milker to see.

It also has a spotlight to help with teat inspection and a backlit panel that makes it easier to see any abnormalities when milk is stripped onto it.

Tracking beyond milking

The GEA FT plant works with the Protrack Vantage system from LIC, a state-of-the-art herd management system that tracks each cow through the milking, the season and beyond.

As she enters the bail her EID tag is read by the Protrack system and identified to LIC’s MINDA, which links the cow to the bail and to her records in MINDA – LIC’s farm record management system.

If need be the cow is automatically drafted by Protrack as she leaves the dairy, or the farmer can enter any cow’s number into the Protrack touch screen to have her drafted after milking.

At about 90 per cent uptake, the MINDA software is the NZ farmers’ most popular choice for herd management.

Chris’ Protrack system doesn’t just monitor and draft his cows; it also controls the amount of grain each cow receives from PMR Grain System’s in-bail feed delivery system.

PMR’s sales manager David Shaw says they’ll be installing a complete feeding system in Chris’ dairy.

“It will have a GSI 200 tonne fully-stiffened silo over a concrete cone.

“From the silo an auger will carry the grain to a Wakely two tonne per hour roller mill, then by another auger to a GSI five tonne meal hopper with a 60 degree bolted cone, all controlled by a Laser Mill control unit.”

David says PMR service all forms of farming and the Wakely mill can be adjusted quickly and easily to suit any application “and it’s capable of processing a wide range of cereal crops”.

“From the hopper a 90mm flexible coreless auger – controlled by Protrack – carries the meal to the bails and drops it into our fully-welded stainless steel feed troughs,” says David.

CIB

Impressed by quality

PMR is another Hinds-based company, but Chris went a little further afield for his refrigeration needs – all the way to Ashburton-based Stewart & Holland because he’s impressed by the quality of their gear.

Stewart & Holland manager Mark Cartwright says Chris’ refrigeration set-up is pretty standard, with a Patton Pak unit and Desuperheater heat exchange that chills the milk and provides water to the gas hot water system at 40-50 degrees Celsius.

“Probably the most innovative equipment we’ll be installing are the electronic valves on the silo, they’re a lot faster than the standard expansion valves.”

It’s set to be a very comprehensive and flexible hightech system with a future-proofing path that should be at the forefront of dairy technology for years to come – something Chris’ new 50/50 equity partners Craig and Hannah Fulton will certainly appreciate.

And Chris? Him and Josh are going back to their roots – a nice dry stock unit near Cheviot, north of Christchurch.

By Graeme Dobson

Dairy Refrigeration

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A work in p

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These calves weren’t waiting for the dairy.

PAYNE

Page 98

Coast & Country

A winning formula in the Waikato Father and son farmers Rex and Brad Payne’s state-of-the-art 60-bail rotary was still a work in progress in June, but they could afford to be laid back about it.

The old 40-aside herringbone was still standing and there’s no drama milking in that for a while, if they needed to.

But once the new rotary’s up and running, the old herringbone will be used to milk colostrum and penicillin cows – and the old yards will be used for both dairies.

GEA Milfos iPUDS and bailgates mounted on the latest bail design.

GEA Farm Technologies area sales manager Paul Gilling, farmer Brad Payne, and Dairyworx owner Hayden Aymes.

Back in June there was still plenty of ground preparation and earthworks to be done and Curin Contracting was hard at work levelling tracks and tanker access.

The Paynes milk 650 cows – and graze 200 calves and 200 rising two-year-olds – on 195 hectares.

Top operator

In this part of the Waikato – a little bit south of Cambridge – the flat land is a mix of sand and peat. And when it came to the earthworks for the new dairy, the Paynes found they had a fair bit of work to do.

About 600 trailer-loads of muddy soil had to be removed and then backfilled with good sand for a solid foundation.

That needed a top operator, but when they

first came to the area the Paynes didn’t know any local contractors – so finding a good one was trial and error.

“We went through a few digger operators until we got in with Steve Curin,” says Brad.

“He [Steve] did a good job and so we stuck with him – and now we’ve built up a good relationship,” says Brad.

“He carts all our fertiliser as well – and if we need anything brought in with a truck and trailer he’s the man, I just have to text him and it gets done”.

Once Steve had prepared and consolidated the site, Kevin Ireland from Challenger Enterprises set about the building.

As with most dairy builds, there was a story attached to how farmer and builder came

together. “About three or four years ago Kevin sent out flyers for feed bunkers,” says Brad.

“He [Kevin] gave me good prices so we had him sort out our bunkers. Then I had him extend the feed pad and it all sort of grew from there. Eventually I asked: ‘Do you build cowsheds?’ and the rest’s history”.

It turned out Kevin’s been building dairies for a long time, both here and in the UK, so Rex and Brad had no hesitation asking him to do their job.

“Kevin had all the computer designing programs and a lot of very good ideas,” says Brad.

“We told him what we wanted and he put it in, but the build has always been flexible.

“There’s been no problem changing things if we saw a way that might work better, so it has

Payne always evolved in the right direction, which is a good thing. He hasn’t had a bad idea yet.”

And Kevin is still evolving his business to keep up with the times and is currently involved with a number of buildings throughout the country to house robotic milkers.

Just shy of robots

Not that there’s anything dated about this job – short of robots it has the best modern technology GEA Technologies has to offer.

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PAYNE

PH 07 578 0030

Page 99

Technology just short of robots at Payne

Father and son farmers Rex and Brad Payne’s state-of-the-art 60-bail rotary was still a work in progress in June.

The old dairy that came with the farm has a ‘mix and match’ of all sorts of milking machines, but it’s GEA Milfos all the way for the new build.

“There were a number of reasons we decided to go with GEA Milfos plant in the new dairy, but mainly because whenever Dad put anything new in, he always went to Milfos,” says Brad.

And they haven’t skimped on technology – they’ve gone from very little in the old herringbone to all the considerable technology GEA has to offer, stopping just short of installing robots.

“Once everything is running smoothly this will be a one-person operation,” says Brad.

“It’ll be interesting to see how much more efficient it makes milking and how much time we save – I’m expecting a lot.”

The one person operation will take over from the minimum two staff needed in the old dairy, and milking will be in two herds with rotating staff.

The in-bail feed bins have individual drainage for easy cleaning.

“One person can do it if needed, but it’s more than 2500 cups to put on – and no one wants to do that on a regular basis. You have to look after your staff,” says Brad.

When the building was weatherproofed, and the Milfos platform was in place, Dairyworx owner Hayden Aymes installed all the GEA Milfos milking system.

Having everthing

As Brad says, this dairy has everything, starting with the new Gen2 bail made from galvanised steel box section that allows all the components to be integrated.

Hayden says it was really simple to install.

“Everything is contained inside the box section.

“It’s very tidy with everything pre-mounted”.

Hayden fitted the bails with the Milfos iCRS cow restraints, Milfos iCR cup removers and the Milfos drop down system rams.

GEA Farm Technologies area manager Paul Gilling says the drop down system allows the

The real technology is under the platform.

cluster to drop down and pass under the bridge once the cow has finished milking.

“This allows the cow to exit the platform without getting caught up in any rubberware,” says Paul.

“The iCR cup-remover and bail-restraint system allows you to retain a cow on the platform if she hasn’t milked out, because she’s kicked the cups off or hasn’t reached her prerecognised flow rate. The bail restraint remains down, a red light shows in the iPUD and she goes around again.”

The Milfos iPUD, or Platform Universal Device, is mounted on the platform between the cow’s legs and provides a ‘heads down’ display of warning lights and a backlit white screen that makes it easy to pick up clots or abnormalities in stripped milk.

Another feature of the iPUD is automatic teat spraying after the cluster is removed, providing teat spray at the optimum time with the best coverage possible.

The Milfos heads-down iPUD was released at last year’s National Fieldays, and it’s already proving very popular.

The iNTELLAB units are mounted under each bail and iNTELSENSE units under every fourth bail to collect almost every conceivable piece of data – milk yield, protein, fat, somatic cell count, conductivity and temperature.

There are 800 connections under the platform alone, so this installation was no small job for Hayden and his Dairyworx crew.

Added to all this technology is HEATIME – each cow has a collar that measures her rumination and activity as she enters and leaves the dairy, which are parameters used to determine when she’s on heat.

When heat is detected she’s automatically drafted by the complex six-way drafting system, where a cow can potentially end up in any one of six holding yards, depending on what she’s wanted for.

PAYNE

Page 100

Coast & Country

Big bang for bucks in Brad’s new dairy

Digger operator Steve Curin sorted the earthworks at Rex and Brad Payne’s new dairy.

The GEA Milfos iPUD.

But wherever she ends up, she’ll be dry, because Brad has had all of the animal-handling yards included under the big 864m2 roof.

Cooling sorted

Payne

The technology continues with the cooling unit, also installed by Dairyworx.

This is a GEA iCONVERTER AquaTESS thermal storage system, an insulated tank full of super-cooled phase-change nodules surrounded by glycol that is more than capable of meeting the new milk chilling regulations that are due to come in in the next few years.

The Payne family has stuck with GEA Farm Technologies all the way in this dairy, even the detergents and chemicals are supplied by FIL, owned by GEA. “We’ve been with FIL ever since Noah was a boy,” says Brad.

“In fact the same person we dealt with back in Huntly is still supplying us with all our deter-

Even the treatment yards are all under cover. gents and teat spray.

“Until now FIL also supplied our tail paint, but with heat detection in the new dairy we won’t be needing that this season.

“The main thing is that they’re reliable – ring or text and they’ll have whatever you need here in two days, or in an emergency during the same day,” says Brad.

“I can’t ask any more than that – if you get good service like that, you stick with it.”

Treatments aren’t the only thing recorded in the Milfos system. For example, as each cow leaves the platform she’s weighed and her weight used to determine her individual in-bail feed regime.

Feeding energy

Bustercover supplied and installed the equipment to store this high-energy feed, grind it into meal and get it to the feed heads in the dairy.

The GEA Milfos machinery all ready to be hooked up.

From there the iDENTITY herd management system takes over and delivers it in the predetermined amount to the feed bins in each bail.

Although the dairy wasn’t ready for Bustercover when New Farm Dairies visited, Brad had it all planned.

“There’s to be two 16-tonne silos and two feed heads with individual feeding into bails.

We will be able to feed to yield if we want to – cows that are doing that bit better deserve to get a bit more high energy feed,” says Brad.

That extra energy comes from a range of products from several sources, depending on price and what is available at the time.

Last year it was BLM Feeds Ltd that supplied quality Dried Distillers Grains.

BLM Feeds Ltd commercial manager Doug Mascull says the company sources DDGS from Australia.

“It’s a byproduct of ethanol manufacture and

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is an excellent protein source.

“In fact digestible protein is 80 per cent of the crude protein content so that the product is not only very palatable, but compared to palm kernel there is very little wastage.”

In other words DDGS represent much better ‘bang for the buck’ and Brad always has an eye for value for money as well as reliability – and he’s got both from BLM Feeds.

In fact the Paynes seem to have got excellent bang for their bucks right across this whole project, all the way from the ground preparation right through the build and plant to the in-dairy feed.

The shed has the best technology on offer anywhere in the world – and it should see this father-and-son team comfortably through to the fast-approaching robot age.

By Graeme Dobson

PAYNE

PH 07 578 0030

Page 101

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LOTTISHAM

Page 102

Coast & Country

Lottisham

Hutchies managing director Brendan Paul, farm owner Bruce Darby, Thorburn Builders’ contracts manager Paul Taylor, Waikato Milking Systems’ Waikato area sales manager Gary Feeney and farm manager Phillip Darby.

The Lottisham family farm’s father and son, Bruce and Phillip Darby, in front of their new dairy.

New dairy for new generation in the shed Bruce and Kay Darby had good reason to look forward to June 1.

It was the date their son Phillip was coming home to start as manager on the new farm.

The Darby family has been dairy farming for a number of years at Ruawaro near Huntly in the Waikato.

In October 2013 there was an opportunity to buy an existing dairy farm just down the road from the home farm.

“The new farm is 167 hectares in total with 161 hectares effective and we winter-milked 415 cows,” says Bruce.

“The farm had been in the same family for years and was split up at one time, then amalgamated, turned into a deer farm and back into a dairy farm.

“It had a dairy shed on it but it was situated in the corner of the property and not practical,

so we decided to build a new dairy shed with a central location,” says Bruce.

The new farm is called Lottisham after a small village in Somerset, England, where Bruce’s ancestors came from.

“We go back and visit quite often; one year we did a farm swap for a few months, so we thought we would like to name it ‘Lottisham’,” says Bruce.

Bruce had built two rotary dairy sheds on the home farm. The first was a 32-bail and eventually became too small, and seven years ago he built a 54-bail rotary to accommodate 600 cows.

“At Lottisham we decided on a 40-aside herringbone dairy shed for simplicity and low maintenance,” says Bruce.

Knowing quality

“I had used Thorburn Builders from Huntly for my other dairy sheds, so knew the quality of their work and could rely on them to complete the job on time.

Thorburn Builders’ contracts manager Paul Taylor says he did a lot of pre-planning with Bruce, making sure the dairy shed was sited in the best place and fitted in with the limitation of the hills.

“The feed pad and silage bunkers were positioned to allow for easy cow movement and machinery access between the three areas.

“Things like drains running in the right direction and good cow flow are important to the functionality of the dairy shed, as it can’t be done retrospectively,” says Paul.

The dairy shed is cream-coloured Coloursteel cladding, which is aesthetically appealing and easy to keep clean.

The shed is a standard herringbone design with a few adjustments to meet Bruce’s requirements.

Thorburn Builders cover the Waikato and South Auckland area offering a full dairy shed package and can organise sub-contractors, which means the farmer is just dealing with one person.

Smart choice The dairy shed has a Waikato Milking Systems 40-aside herringbone milking machine and has proved to be a smart choice.

Fitted by Hutchies, of Morrinsville and Taupiri, it’s a Waikato Supa4 Herringbone with an automatic SmartWASH for washing the plant and vat and Swing Down Jetters for easier washing of the cups.

The herringbone is fitted with SmartPULS – a digital pulsation system that effectively controls the milking and rest phases of pulsation to ensure a clean milk-out and good udder health.

Having correct milking and rest phases reduces discomfort for cows and reduces new mastitis infections. With SmartPULS, pulsation can be customised to suit each herd.

The Darby’s herringbone is fitted with a blower vacuum pump with an efficient SmartDRIVE controller from Waikato Milking Systems, which speeds the vacuum pump up or down depending on vacuum demand.

LOTTISHAM

PH 07 578 0030

Page 103

One new herringbone beats two old rotaries The vacuum pump controller provides power savings of up to 47 per cent.

Waikato Milking Systems’ Waikato area sales manager Gary Feeney has been involved with milking machines for most of his working life and at one stage was a dairy inspector.

“Waikato Milking Systems milking plants are a good reliable product that cater for all budgets and technology requirements,” says Gary.

Hutchies managing director Brendan Paul says his company also installed the double bank industrial cooler “which circulates chilled water to cool the milk to the required temperature before it goes into the vat”.

Top teat care

The Darby’s new dairy shed installation uses FIL hygiene and teat care products and is overseen by FIL’s farm service area manager Mark Mohring.

The FIL Quantum hygiene range of products, Quantum Blue Acid and Quantum XL Alkali, are programmed into the automatic dispensing and wash system for both the milking plant and silo, for achieving ongoing excellence in

milk quality results.

“The initial testing and programming of the automatic wash system and functions, in conjunction with Hutchies, is to achieve a combined net result of the best utilisation of FIL products, water resources and meet all compliance and milk supply requirements for Bruce and Kay’s dairy unit,” says Mark.

The Reid and Harrison’s Yardmaster pond stirrer for the effluent pond was supplied and installed by Hutchies.

Stirrer solution

“The stirrer keeps the solids in the pond in solution until ready for irrigation when required. The green water from the yard washing is recycled and supplies the wash for the feed pad, which saves on water,” says Brendan.

Hutchies also supplied and installed the water reticulation system, variable speed wash down pump, which speeds up or down depending on demand, and the digital dosing system for dispensing minerals into the toughs for the cows.

WRS Refrigeration Ltd owner Mike Barnett says the shed’s refrigeration system has future-

proofed the farm for Fonterra’s new regulations coming into effect for the 2015-2016 season.

“Under the new regulations milk mixing temperatures must not exceed 10 degrees Celsius. The best option to achieve this is with pre-cooling.

Dropping degrees

“We chill water in a bulk tank to six degrees Celsius and then this is circulated through a double bank plate cooler,” says Mike.

“The milk enters the vat at about eight degrees Celsius; the milk is then cooled to four degrees Celsius by a second smaller refrigeration unit.”

Mike says anytime you’re making “cold” it costs, so to offset these costs the Lottisham Farm got WRS Refrigeration Ltd to install a Mahana Blue hot water heat reclaim system, which will make in excess of 80 degrees Celsius hot water.

“This type of system is what I’m recommending to all our customers who are installing new equipment – and we have many variances of this system to suit small to medium farms as

The herringbone dairy where the cows enter from.

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well,” says Mike, who has been in the refrigeration business for 17 years and covers South Auckland and North Waikato, providing a 24-hour seven-day back-up service.

Third biggie

The new Lottisham shed is the third big project Rivertown Electrical has worked on for Bruce and Kay Darby.

“We did all the electrical wiring in the other two dairy sheds as well, and it’s always a pleasure,” says Clint Robinson, who is part-owner of the Huntly-based business.

Rivertown Electrical wired up the milking system, automatic vat and plant wash, effluent pump and have been the Darby’s farm electricians for many years.

They cover the greater Waikato area, providing 24-hour seven-day full back-up service.

The new dairy shed has cut milking time and is well equipped to handle year-round milking.

Now that son Phillip is managing the farm, Bruce can look forward to spending less time in the shed.

WRS Refrigeration Ltd owner Mike Barnett with the refrigeration units.

By Helen Wilson

Farm owner Bruce Darby and Hutchies’ managing director Brendan Paul.

ROWLING

Page 104

Coast & Country

Rowlings roll-out new dairy for future Everything has a use-by date â&#x20AC;&#x201C; and Neil Rowling reckoned his old 34-aside herringbone dairy shed was well past expiration.

By Helen Wilson

â&#x20AC;&#x153;It started life as a 12-aside herringbone; and as we bought more land and increased the size of the herd, it was added onto and rearranged,â&#x20AC;? says Neil. â&#x20AC;&#x153;It just became too slow and too small and we wanted to attract good staff, so it was time to upgrade and build a new dairy shed.â&#x20AC;?

Neil and Gay Rowling own Camborne Holdings Ltd, a 195 hectare dairy farm at Tauhei in the Waikato.

The original farm has been added to during 40 years the couple has been there and the herdâ&#x20AC;&#x2122;s increased to 560 cows run in two mobs.

The old dairy shed required two milkers and another person to get the cows in and change the yards.

But with the new 54-bail rotary,

only one person is needed to milk, so other staff can focus on other farm jobs. â&#x20AC;&#x153;I knew Don Chapmanâ&#x20AC;&#x2122;s reputation as a quality dairy builder so I got in touch with him and during a period of several months we put a plan together â&#x20AC;&#x201C; and once I was happy with it we started the building,â&#x20AC;? says Neil.

Don Chapman of Chapman Dairy Ltd of Morrinsville in the Waikato has been building farm dairies for more than 45 years and all have stood the test of time.

Different design

â&#x20AC;&#x153;Neil decided on a 54-bail rotary dairy and this one is a little different to my standard design,â&#x20AC;? says Don. â&#x20AC;&#x153;We have extended the building at the front for weather cover, and the underpass into the centre well is accessible from outside the dairy, which is like a service entry so contractors can just park their vehicle and have direct access instead of going through the dairy,â&#x20AC;? says Don. There are no windows in the

exterior walls of the milking platform area. â&#x20AC;&#x153;They only get dirty anyway,â&#x20AC;? says Neil.

Instead are several solid sliding doors that keep out the cold weather and can be opened up during summer to allow a breeze through making the dairy light and airy.

Thereâ&#x20AC;&#x2122;s also a milking pit around the platform, which stops efďŹ&#x201A;uent spraying on to the dairy walls.

Plus plenty of room in the animal handling area â&#x20AC;&#x201C; and being under cover â&#x20AC;&#x201C; makes it easier to work on animals in bad weather. â&#x20AC;&#x153;This rotary dairy has everything I wanted and came in within budget.

Don did a great job,â&#x20AC;? says Neil.

McLarens Rural Services from Morrinsville and Huntly is one of the Waikato service partners for GEA Farm Technologies and installed the new milking plant. They also provide scheduled preventative maintenance for Neil.

The new rotary dairy viewed from the yard.

New Gen2 bail

GEA Farm Technologies supplied the Milfos iCONVEYOR milking machine attached to the new bail design called Gen2 on the iFLOW double beam rotary platform.

The 54-bail rotary is the ďŹ rst Gen2 bail design installed in New Zealand, and there has been no change to the running gear on the successful iFLOW rotary platform.

GEA Farm Technologies area sales manager Paul Convery says the Gen2 bail is very robust, allowing for the increasing size of New Zealand cows,

and the bail has many functional ergonomic design features. â&#x20AC;&#x153;The iCORE is a new product and is a milking point controller for each bail. It is connected to a central hub, which tells the bail what to do, such as cup removal, teat spraying and pulsation rate. It can be adjusted and monitored,â&#x20AC;? says Paul.

There is an iPUD leg spreader and teat sprayer placed on the platform in each bail.

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The 54-bail rotary platform.

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)RU D PRUH HIâ&#x20AC;Ť Ű&#x2039;â&#x20AC;ŹFLHQW IDUP GDLU\ Li^\bZeblbg` bg _Zkf ]Zbkr ]^lb`g Zg] \hglmkn\mbhg With a lifetime of experience designing and building farm dairies, weâ&#x20AC;&#x2122;re well equipped to create a design that suits your exact needs, no matter what.

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ROWLING

PH 07 578 0030

Page 105

Expiry date means new dairy at Tauhei This makes the cow stand properly for easy cup placement and teat sprays the cow after the cluster is removed, providing teat spray at the optimum time with the best coverage possible.

The iPUD heads down display panel, which is situated in the leg spreader, gives light signals to indicate to the operator what mode the bail is in, right in the working space.

If the clusters are kicked off iCORE will change the iPUD from green to red – alerting the milker that there’s a problem, which can then be quickly rectified.

Another feature of GEA’S iPUD is the ability to strip milk directly onto the white back light panel, which will show up any blood in the milk and signal a possible mastitis problem.

FIL area sales manager Mark Mohring.

The iPUD also has a spotlight function, which lights up the cow’s udder so it can be clearly seen for any teat or health issues. The high standard dairy incorporates iNTELLAB, which through iCORE provides data to the farmer comprising of yield, fat, protein, lactose and conductivity per cow every milking allowing the farmer to make crucial management decisions regarding feed requirements, culling and drafting.

The cows are automatically drafted into the correct yard according to parameters pre-determined by the farm manager, says Paul.

“The automatic cup removers are also controlled through iCORE. All settings related to cluster removal are easily adjusted.

Paul says the iC330 cluster has a sight glass on each shell, which indicates a split in any liner. “Another feature of the milking plant is the 3C centre gland, which enables the wash water to get to the plant under the concrete allowing the plant to wash while rotating. The 3C gland eliminates the need to plumb wash water overhead.” says Paul.

Washing up

FIL area sales manager Mark Mohring says his company was part of the dairy set-up from an early stage.

“We individualise a wash programme for each dairy shed to achieve compliance dairy hygiene results. Fonterra set the standards and the parameters,” says Mark.

The wash programme depends on water quality and the design of the plant.

The Herdflow backing gate.

GEA Farm Technologies area sales manager Paul Convery inspects a cluster.

Automatic scrubbing brush.

“We work closely with GEA Farm Technologies to ensure an excellent result,” says Mark.

The automated system is checked regularly for its performance and adjustments can be made if required.

The system can be remotely monitored at the farm through the Fonterra network.

FIL will also give on-farm training to the farmer and staff about plant cleaning assuring the highest standards.

Don Chapman, of Chapman Dairy Ltd, and farm owner Neil Rowling stand in front of the dairy.

ROWLING

Page 106

Coast & Country

One in the shed means two on the farm FIL also supply animal health care products, such as iodine based teat spray Iodoshield Active with a manuka honey additive.

“We are getting good results with this and it is the most effective teat spray for this farm,” says Mark, who says FIL provide a full back-up service if needed.

The large rectangular yard has a slope on it so when the flood wash system is switched on to clean the yard, the green wash flows straight into the effluent storage pit to be distributed as solid or liquid effluent.

No hurt cows

The Rowlings have gone with the latest technology in backing gates. They’ve chosen the Herdflow Crowd Gate with standard breech sensor, which prevents the cows from

The pit area around the platform.

The push button control system.

being pushed too hard.

Meanwhile, the Cow Detector prevents cows from being hurt as the gate descends in amongst the herd. It also has the automated wash system.

With the Herdflow Wash System, the operator just has to push the wash button and the backing gate does the rest leaving a Dungbuster clean yard and the gate ready to receive the next herd of cows.

Other standard features include the pinch drive system onto an ‘I’ beam to minimise slippage and eliminate derailing, two-speed forward and reverse, and the high low-rail option allowing cows to move into a side pen under the gate rail.

Leask Engineering from Morrinsville completed all the welding in the yard and another Morrinsville company Ace Electrical

made sure all the electrical work was carried out to perfection.

Neil and Gay’s daughter Amanda works part-time on the farm rearing the calves and is the ‘It girl’.

She uses her computer skills to collate the farm data and passes the information to her father, who can make decide on the next plan of action.

Neil has put one set of cups on a cow in the new dairy shed. “I like to stay comfortable.

“It’s been a good move to build a new dairy shed and we have had a good payout this year. Hopefully, we have seen the end of droughts for a while,” says Neil.

And what happened to the old milking plant? “I sold it to another farmer, so it’s probably still being used in

By Helen Wilson another dairy shed.”

Rowling

The central well.

The cow exit area.

Effluent holding tank.

GEA Farm Technologies area sales manager Paul Convery, FIL area sales manager Mark Mohring, farm owner Neil Rowling and Don Chapman of Chapman Dairy Ltd.

ROWLING

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Page 1 108

LYNRICH TRUST

Coast & Country

Not over the top with technology The Jersey herd, with the new dairy in the background.

Richard and Christine Lansdaal bought this 100 hectare Morrinsville property 20 years ago and steadily expanded to 200ha, milking 700 Jerseys.

inson install a Waikato Milking Systems’ plant in their new dairy.

Then a couple of years ago they started thinking – if they split the farm into two units, the cows would do better with Builder Don Chapman, with farm owners only 350 on each farm. And their work Christine and Richard Lansdaal. would be halved.

So they divided farm and herd exactly in half, kept half and set up the other as roofed herringbone was pretty straightforward an independent operation with a brand new for them – but there is a couple of innovations.

36-aside herringbone dairy and a sharemilker.

There’s a recess in the pit wall for the test But why choose a herringbone? Richard says bucket and a ‘step rail’ running along each side the shed is simple, efficient and effective. of the pit.

“Anyone can walk in and milk, whereas with Water goes through the rail on one side, but a rotary – at least the old rotary we have on the its main purpose is for the milker to stand on other property – you have to know what you’re to easily reach the cows’ backs to check and doing or things can go bad very quickly.” mark them.

The yards attached to the dairy incorporate a feed pad, a shelter for the Artificial Insemina40-year specialist tion technician and vet, and a side holding The Lansdaal’s new dairy was designed and race for AI and fortnightly immune-boosting built by Morrinsville-based dairy specialist Don Chapman from Chapman Dairy, together injections for Fonterra’s Stolle milk products.

At either end of the yards – at the top of the with David Leask from nearby Tatuanui-based entrance yard and at the bottom of the feed Leask Engineering. pad and holding race – Don has installed a Don’s been in the dairy design and build ‘weeping wall’ pit where solids are filtered out business for more than 40 years, most of them before the effluent goes to the pond. working with Leasks, so the Lansdaal’s flat-

Looking back into the shed from the yard.

And this is where Richard put in an initiative of his own – he’s recycling the filtered green water to flood-wash the yard.

Engineering the yard

Between the buildings and all the yarding was a huge amount of steelwork for Leask Engineering to do.

Leask Engineering has been in business and specialising in dairies since 1958. David Leask says his father invented adjustable breast rails for herringbone sheds.

Leask Engineering will supply and install complete sheds, or supply kitsets or just selected components to other engineers.

And they’ll do any other engineering jobs that come their way. Their reputation has gone far beyond the Waikato – in fact they’ve been selling and installing steelwork in dairies as far away as Ireland and Pakistan and several places in between.

Staying local, the Lansdaals had Geo Hutch-

Easy to use

‘Hutchies’, as they’re known locally, are Waikato Milking Systems’ Morrinsville agents.

“We’ve dealt with Hutchies for 25 years, they’ve been so good to us we just wanted to stick with them and Waikato [Milking Systems],” says Christine.

And they have every reason to want to stay with Waikato Milking Systems – they’re a 100 per cent New Zealand-owned company with global reach.

Waikato Milking Systems has more than 30 dealers nationwide and trade in more than 30 countries worldwide.

Hutchies’ managing director Brendan Paul says they installed a Supa4 milking system with a blower pump, a high performance variable speed drive enabling power savings of up to 47 per cent, a SmartDRIVE Milk Pump Controller which gives more efficient cooling, and a FloMax Milk Pump.

The Waikato Milking Systems’ plant also features a Smart Controller for the

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LYNRICH TRUST

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Lynrich Trust

David Leask shows off the Leask Engineering bails.

cup removers, a Maxi Milk Filter and a double-bank SupaFlo Industrial Plate Cooler – all in all technology that’s remarkably easy to use and provides a very efficient system.

And customers can choose to add new generation technology at any time such as SmartD-TECT, Waikato Milking Systems’ intelligent mastitis alert system.

Last, but definitely not least in the efficiency stakes on the Lansdaals’ plant, is the Swing Arms to keep the pit area clear of hanging hoses and swing-down jetter brackets so the jetter line is up and out of the way during milking.

But Hutchies didn’t just install the milking plant, they did all of the pumps and plumbing. Hutchies can do everything that involves moving or storing liquids on or off the farm, whether it’s installing the gear or just selling any of the pumps and equipment they’re agents for.

And Hutchies is another local firm spreading their wings overseas – they’ve been working in South America’s developing dairy industry,

particularly in Brazil where a group of NZ dairy farmers have set up dairy farms.

Drafting the girls

Out in the yard, the Lansdaals have installed a high-tech LIC Protrack automated drafting gate.

With the LIC gate the manager can draft out any cow just by putting her number into the console at the end of the pit – she’ll find herself neatly separated out and in a side yard waiting for attention before she knows it.

And it’s not just in the shed cows can be selected for drafting.

“If he’s out on the farm and sees a cow he wants a closer look at he just puts her number into the LIC system with his phone and she’ll be picked up at the next milking,” says Richard.

The LIC Protrack is catching on in a big way – there’s 1300 Protrack gates in NZ now and the number is growing all the time.

NZ Specialist Coatings, specialists in industrial flooring, epoxy floor and wall coatings,

Hutchies’ managing director Brendan Paul checks the WMS Smart Drive. and floor grinding, added the finishing touch.

The Lansdaal’s job was not a big one for them – most of the dairy is galvanised steel, so just the pit needed sealing with a high gloss, acid-resistant and non-stick protective coating.

But Specialist Coatings took the same care as they do with all their work and Richard is more than happy with the job and the blokes who done it.

Locating good water

Being a new site, the dairy needed its own water supply, so Mike and Chris Ornsby from Waikato-based Barham United Well drillers put down a bore right beside it.

The Barham team had no problems locating good water – a bit of a rarity in the area, apparently – and they came on time, drilled, and were gone again in only three or four days.

There was no fuss – but that’s just what Richard expected from such an experienced and professional crew.

It’s not just water bores Barham United is experienced in – their versatile staff offer a

Richard Lansdaal’s self-installed green water flood-wash in action.

range of services from repairs and maintenance of bores and pumps to oil extraction and mining.

Once Barham sorted the water supply, the Lansdaals needed somewhere to store it. For this they chose Promax plastic tanks.

Promax offered them a range of high quality, smooth-sided water tanks from 10,000 litres to 30,000L capacity – all compliant with AS/ NZ Standards for drinking water, all with the Promax 10-year warranty and free site delivery.

“They came exactly when they said they would, no hassles or delays,” says Richard. “I can’t ask for more than that.”

And Promax don’t just do water tanks; they’re leaders in all aspects of liquid storage and transport, drainage, storage boxes and bins, and even markers and barrier systems.

“The whole job came together with minimum stress,” says Richard.

“Don and all the crew turned out to be as flexible, approachable and friendly as we’d been told we could expect. I can’t ask for

By Graeme Dobson more than that.”

CRANLEIGH

Page 110

Coast & Country

Do it once and do it right DIY and environmentally-friendly – this dairy’s a collection of Kiwi ingenuity that makes it a winner from all angles.

When New Farm Dairies visits, Alan Henderson’s 300 hectares Te Awamutu farm is in near drought and looks a lot like Central Queensland. There isn’t much grass for his 640 cows, but thanks to good planning he’s still milking twice-a-day.

When his family bought the property in 1952 they ran sheep.

Then they converted to beef, cropping and finally – 31 years ago – went into dairy.

Alan’s kept it diverse with some drystock, cropping and now kiwifruit, nashi, apples and 50ha of fodder crops to see him through the droughts.

And he rears 600-700 calves to keep busy during winter.

Alan plans everything ahead, so when he replaced his old rotary he used the principle ‘do it once and do it right’ to plan, design and project manage it himself.

“It’s cheaper to build floor area once; if you think half a metre is going to be comfortable, add another 300mm onto it and you should be right,” says Alan.

The dairy he’s designed is big; he reckons he could drive his four-wheeler all the way round the platform.

Space

That’s not just for future expansion, Alan likes space.

He says it’s much more comfortable for workers and cows. He started planning the job six months before the first sod was turned and thoroughly researched buildings and milking plants.

Then, once he’d decided on exactly what he wanted, he did his research on sub-contractors for the work he and his staff couldn’t do themselves – DIY can only go so far.

He needed an experienced dairy builder, so he looked at new dairies in his area and talked to other farmers before settling on Hamilton-based About Time Builders.

About Time Builders is a family-owned and operated business that’s been building dairies since 2000.

WMS’ Heath Lunjevich, Alan Henderson, Any Angle Roofing’s Shaun Higginson and WMS’ Josh Janmaat.

About Time Builder’s manager Gary Pepperell says farm buildings form a major part of their business, but they’ll take on pretty much anything.

“We’ve built a reputation around going that extra mile to work around the customer’s needs and meet their expectations.

Alan was easy; he knew what he wanted,” says Gary.

Alan had specific requirements for cladding, so he called Shaun and Jenaya Higginson, owner/managers of Te Awamutubased Any Angle Roofing.

Shaun is a licenced building practitioner with more than 15 years’ experience in the roofing and cladding business – and he came highly recommended.

Alan wanted Colorsteel exterior cladding

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on the dairy; and as a specialist in long run roofing, this was right up Shaun’s alley. He’s done a job Alan can be proud of, and he gives a five-year warranty on his workmanship.

Alan wanted a fully integrated milking system, so he did his research (of course) and Waikato Milking Systems came out on top on all counts.

“I went for Waikato because of the simplicity and quality of their plant, and their reliable local service,” says Alan.

Local Waikato Milking Systems agent Jeremy Collett explains the finer details of the plant he’s installed.

“Alan’s got a 60-bail Centrus rotary platform fitted with SmartECRs electronic cup removers, BailGate Straps to keep the cow in the bail if she kicks the cups off, and an

Cranleigh The dairy building and yards with Alan’s powergenerating solar panels.

auto plant wash to make things easier for the milker. “We also fitted a Milk Recovery System that uses compressed air to push the milk remaining in the pipes through before the cleaning cycle starts.”

The plant also features a SmartPULS digital pulsation system and a Hush Kit along with a standard Waikato Orbitor Gland, 320 Claws and a G2 Cluster Washer.

The plant is controlled through a SmartCONTROL touch screen controller, all very efficient – just as Alan planned it. But it’s the clean lines of Waikato’s Centrus platform that catch the eye.

Waikato’s Centrus division manager Josh Janmaat says Centrus platforms are a fibreglass composite – and 22 tonne lighter than the equivalent concrete platform.

CRANLEIGH

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New dairy is energy and water-saver As with every other contractor and product he put into the shed, Alan did his homework and discovered Dairy Wall Coatings and Acraflex have built an excellent reputation for service and quality; and their 10-year guarantee on all new dairy applications is a winner.

Versatility Effluent ponds with fodder crops in the distance, waiting to be harvested.

Waikato Milking System’s Centrus Platform.

“It’s 80 per cent lighter, meaning less wear and a considerable saving in overall maintenance and energy needs,” says Josh.

“The platforms come in 54-bail or 60-bail, but they’re 40 per cent more expensive than concrete, so we intended them for export, but they’ve proved so popular here that after five years we’re only now exporting our first – to Russia.”

Alan made more big energy savings by installing a Waikato Milking Systems SmartDRIVE variable speed drive on a Fristam milk pump and a Blower Vacuum Pump BP400 – and overhead he had Murray Withers from Withers Electrical install power-saving LED lighting when

The old platform, retired to the paddock beside the new dairy.

he powered the dairy.

About 80 per cent of his clients are rural, so Murray’s tuned to farmers’ needs – and he says Alan’s a bit different – more hands on.

“Alan did all of the ducting himself, so we could get on with installing the Waikato Milking Systems gear and wiring up his green water effluent wash,” says Murray.

And they have the same work ethic. “We never go back to a job because we do it right the first time.”

Power chill

It wasn’t all new gear that Murray wired in. Alan kept the Power Chill (NZ) Ltd refrigeration plant from his old dairy because

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it’s a reliable unit and he can rely on Power Chill’s service.

They’ve been dealing with farmer’s needs in the Waikato and the King Country for more than 12 years and offer a complete design and installation package using the world’s leading brands.

Their work is all backed by a comprehensive preventative maintenance programme with 24/7 back-up service.

For the finishing touch, Alan had Dairy Wall Coatings apply a protective Acraflex Dairy Wall Coating system. Acraflex seals the concrete against bacterial build-up; it’s hardwearing, easy to clean, looks great and brightens up the dairy.

In the exit race Alan’s installed a piece of technology that’s catching on in a big way in NZ – an LIC Protrack automated drafting gate.

Its popularity lies in its versatility and huge labour savings when it comes to drafting – the milker simply puts a cow’s number into a console and she’s neatly drafted out before she knows it.

And a cow can be selected from anywhere; just put her number into the LIC system with a cellphone and she’ll be picked up at the next milking. Couldn’t be easier. Tucked away to one side of the yard, Alan is installing another labour-saving device; a Wrangler hoof trimming press, created by Wilco and Waverley Klein Ovink. Many farmers rate the Wrangler as one of the most valuable pieces of equipment on the farm, and it does it all without a computer – in fact without any electronics at all.

The Wrangler uses a system of slings and ropes to manually – but easily – lift and restrain each leg so the hoof can be worked on accurately and safely.

The energy-saving Wrangler epitomises Alan’s approach to his business, his dairy is one of the most environmentally-friendly and miserly – both in energy and water – I’ve ever come across.

By using energy-efficient equipment and LED lighting, he’s kept his power consumption at the same level as when operating his old 28-bail dairy. And up on the roof he’s installing a massive array of solar panels that will ultimately cut this by a further 30 per cent.

Water consumption is even more frugal. Alan’s halved his water use by reusing water five times from the chiller through cleaning cycles to the green water washdown.

By Graeme Dobson

HILLS

Page 112

Coast & Country

The Aztech goat barns are light and airy, designed with goat comfort in mind.

Land of milk and opportunity for South African family New Zealand is a land of opportunity – a country where initiative and hard work is rewarded – believes Jamie Hills, who arrived here from South Africa in 2005.

Since then his parents James and Wendy have joined him, and together they have established a milking goat farm near the village of Whatawhata near Hamilton.

The family sheep and beef farmers in Klerksdorp near the city of Potchefstroom in the North West province of South Africa.

Jamie’s sister, Theresa, was the first to come to New Zealand, enthusiastically encouraging her family to emigrate too.

Jamie’s first job was milking cows. “I pretty quickly figured out I didn’t want to be working for someone else all my life, but getting into the dairy industry was going to be too expensive.”

Business opportunity

Jamie’s next job was working for Campbell Storey, a shareholder of the Dairy Goat Co-op.

There not only did Jamie fall in love with goats, he also discovered milking goats offered a business opportunity for him and his parents.

In 2008 the family bought 30 hectares of bare land near the Waikato village of Whatawhata.

“There was nothing here. It had been a maize block so there were no fences, no building, not even any power,” says Jamie.

He began developing the property, with running a dairy goat farm in mind, all the while sharemilking for Alan Empson, also of the Dairy Goat Co-op – something he continues to do.

“The first thing I built was an implement shed in the middle of what I planned to be the tanker track circuit.” Second on the list was a home for Wendy and James.

Next followed two barns, one for kids and one for the milking goats, built by Aztech Farm Buildings.

Goat comfort

Light and airy, designed with goat comfort in mind, the two large barns feature durable timber pole columns and a steel roofing system with managed light and heat inflow from the sun, thanks to clearlite panels which provide temperature control without making it too hot in summer.

The design ensures there’s nowhere for birds to perch, reducing the risk of feed being con-

sumed by birds and the disease risk from bird droppings in feed.

Aztech Buildings marketing manager Matthew Hoyle says properly designed and managed dairy goat barns, like those on the Hills property, have a significantly positive effect on dairy goat profitability – via enhanced feed conversion efficiency and doe performance, improved animal health and welfare, increased pasture production, decreased pasture or soil damage, improved water use, and decreased environmental impact of the dairy system.

Jamie is pleased with the barns, which he says work well thanks to their design for ease of feeding goats and cleaning out litter, as well as the flow of does to and from the dairy.

Family business, WD Davenport & Co Ltd Builders, built the dairy with daughter Michelle Corlett drawing the 30-aside goat dairy plans.

Peter Davenport managed this project. “It was a straightforward excavation as it was a flat site, and Jamie and James are awesome to work with. They had done their homework and knew what they wanted,” says Peter.

Jamie designed a race system using temporary gates in various configurations to get the right animal flow. The framing for the dairy is

structural steel, giving strength and durability.

The walls are constructed of insulated panels that are also used in cool stores.

“The panels are food safety approved, as they can be easily cleaned. The block walls of the pit area have been painted in a finish, which is also food safety approved and easily cleaned,” says Peter.

The design includes a large span roof area over the yards providing protection from the elements for goats and workers. Leading from the milking area is an office and toilet, plus machinery room and an outside vat stage.

Warren Davenport says all the contractors involved with the dairy worked closely together to ensure the plumbing and electrical services required, now and into the future, were installed before the concrete floor was poured.

Tidy set-up

Hobbs Electrical of Te Awamutu was responsible for wiring the new dairy. Owner Ken Hobbs says the project went smoothly, with good co-operation between other trades and the owners.

“Much of the wiring is pretty standard, apart from what was required for the automatic systems for the milking plant.”

The new TENDO A compact, multifunction jack of all trades

HILLS

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Page 113

Rapid exit stalling system speeds up milking Ken says the goat dairy is a “very tidy set-up” and it was a pleasure to be part of the project.

It was Hayden Aymes, of Dairyworx Otorohanga, who installed the GEA WestfaliaSurge milking equipment in the dairy.

“The equipment used for a goat dairy is not too different from a cow dairy, except of course there are just two cups and you can fit more goats into a smaller area,” says Hayden.

Continuous barrier

What is different is the rapid exit stalling system. That’s a series of hinged rubber ‘gates’ which a goat pushes open as it enters the milking area.

The gate then closes behind it, leaving the adjacent stall for the next goat in line.

When milking is finished the goats are released by lifting the continuous barrier in front of all the stalls, operated from the pit.

Once the goats have left, the barrier is replaced and the second wave of goats come in to be milked, tempted by feed rations delivered to each stall.

“The dairy is running pretty smoothly,” says Hayden. It’s the fourth goat dairy he’s installed equipment in.

Jamie says even in the first few days of milking, milk quality was excellent, with no grades, and he’s delighted.

The only initial problem was the young goats weren’t producing very much milk, so adjustments

had to be made to the vat’s cooling system to cope with smaller volumes.

Best of both

That will no longer be an issue once the herd grows in numbers and maturity.

GEA’s south and west Waikato area sales manager Paul Gilling says Hayden is excellent at his job of installing equipment and working closely with clients to meet their needs.

“What we have done with this dairy is install the best of both Milfos and WestfaliaSurge equipment to provide the best system for the Hill dairy,” says Paul.

Having access to world leading equipment, manufactured in Hamilton is a distinct advantage for clients, he says.

James, who does most of the milking, admits to finding high tech equipment baffling, but says the system Dairyworx and GEA has installed is simple and efficient.

“What I like best is that at the end of milking I just push a button and walk away, and everything gets washed by itself,” says James.

That’s thanks to the iNTELWASH system, which automatically washes the milking equipment using the correct doses of detergent, ensuring the equipment is thoroughly cleaned before the next milking, and eliminating the risk of human error.

The Hills’ dairy is also fitted with Interpuls clusters and jetters.

The vacuum system is the same

as that used in cow dairies, but the vacuum level and pulsation is adjusted for goats.

Paul says Jamie opted for the more expensive Rotary Lobe Milk pump.

“Goats’ milk is easily damaged in the milk harvesting process, which can be an issue in a herringbone shed with an overhead milk line.

“The Rotary Lobe Milk pump is gentler on the milk, meaning milk quality is preserved. In terms of the rest of the plant, it is fairly standard,” says Paul.

“Things are going well in the Hills’ dairy but the first season of milking is always a bit difficult as the animals and farmers get used to the new dairy.”

Giant help

Jamie has a ‘giant’ helping hand when it comes to cleaning the goat houses and other tasks around the farm – in the form of a Giant V5003T wheel loader he bought from ForestQuip.

The loader, with a 60hp Kubota engine is made in Holland and John Hansen of ForestQuip says the unique machine is ideal for the goat industry.

“These machines are designed for European farms where there’s often not a lot of room to manoeuvre, which makes them ideal for working in tight spaces like goat barns.

“They are very powerful and can lift nearly their own weight with a clip hitch system, which means implements can be changed

Caravans4u

Happy goat farmers – James and Wendy Hills and their son Jamie inside the barn for milking goats on their Whatawhata farm.

The 30-aside dairy features a rapid exit stalling system for the goat.

Paul Gilling of GEA Farm Technologies says the Hills dairy has the best of both Milfos and WestfaliaSurge equipment.

Warren and Peter Davenport, of WD Davenport & Co Ltd Builders, built the dairy. without leaving the cab,” says John. says the Giant loader is one of the “The loaders are comfortable to oper- best investments he’s made because of ate with high visibility.” its manoeuvrability, ease of operation Jamie, who first saw the Giant loaders and versatility. at the Mystery Creek Fieldays,

By Elaine Fisher

Your local milking machine and dairy shed specialists

Hayden Aymes 0800 329 679

9 Lawrence Street, Otorohanga hayden@dairyworx.co.nz

HOBBS ELECTRICAL CALL KEN – 07 871 4516 – 0272 848 495

UPSON DOWNS FARM

Page 114

Coast & Country

New Dargaville dairy helps farmer sleep well Off the beaten track in Northlandâ&#x20AC;&#x2122;s Te Kopuru â&#x20AC;&#x201C; lapped by Wairoa River and the West Coast â&#x20AC;&#x201C; stands a dairy epitomising the beneďŹ ts of farmers project-managing their own dream sheds.

Allister and Maree McCahon have been on their farm 20 years â&#x20AC;&#x201C; ďŹ rst as sharemilkers then owners.

The 300ha farm is 260 hectares effective and the Jersey-Friesian herd was milked in a 32-aside herringbone. â&#x20AC;&#x153;The shed wasnâ&#x20AC;&#x2122;t big enough, so we deferred maintenance to build another.â&#x20AC;?

The new 60-bail rotary is operated by two staff and a third brings the 650 cows in. The project started May 2013, with the platform completed before Christmas. Advance Dairy and Pump started the ďŹ t-out of the plant in early-2014.

The timber building stands nearly seven metres tall with a curved roof, but itâ&#x20AC;&#x2122;s whatâ&#x20AC;&#x2122;s inside that makes the dairy highly-beneďŹ cial.

The DeLaval PR1100 rotary platform suits the site â&#x20AC;&#x201C; not far from Te Kopuruâ&#x20AC;&#x2122;s coastline, making steel corrosion from salt air a problem. But no steel-exposed parts underneath can rust, with all seams being concrete.

Platform perfection

The platform was built and installed by Hotter Engineering Ltd. Hotter is an innovator in the dairy world â&#x20AC;&#x201C; in 1969 T.E. Hotter Ltd designed and installed the worldâ&#x20AC;&#x2122;s ďŹ rst rotary platform. â&#x20AC;&#x153;Weâ&#x20AC;&#x2122;ve focused on the continual development of the platforms since this time and have invested heavily in developing intergraded systems to offer a comprehensive range of rotary milking platforms to ďŹ ll every need from the small family-owned farm through to large corporate operations.â&#x20AC;? The

PP PP 0 0 0

Hotter name screams state-of-the-art technology, with itâ&#x20AC;&#x2122;s company Turn-Styles Ltd exporting worldwide.

Twenty years ago Russell Hotter bought the ďŹ rm from his father. Today he still provides the strongest platforms â&#x20AC;&#x201C; and Hotter Engineering continuously researches to keep on top of their game.

Hotterâ&#x20AC;&#x2122;s offers structural steel fabrication and installation, 24-hour on-call service for platform repairs, regular maintenance checks, and theyâ&#x20AC;&#x2122;re specialists in relocation and extension of platforms.

Allister is happy with their work. â&#x20AC;&#x153;They were in and out.â&#x20AC;?

Picking service

The farm team outside the new dairy: workers Nigel and Anna Lim, farm owners Allister and Marie McCahon, with staff member Eli Anderson and manager Sisira Rupasinghe.

Advance Dairy and Pump owner Trevor Hutchinson, with the water pumps his team installed at the McCahonâ&#x20AC;&#x2122;s new dairy.

Advance Dairy and Pump is the local agent for DeLaval â&#x20AC;&#x201C; with Whangarei, Dargaville and Wellsford branches â&#x20AC;&#x201C; and installed the milking plant and all the dairyâ&#x20AC;&#x2122;s pump and water requirements.

Advance Dairy and Pump owner Trevor Hutchinson says the DeLaval plant they ďŹ tted has given the McCahons a simple system with many advantages - including ease of use and a clean low proďŹ le platform, allowing for easier cow ďŹ&#x201A;ow and servicing.

Advance Dairy and Pump is impressed with the DALâ&#x20AC;&#x2122;s North Island sales and marketing manager Shaun Killalea says CellSense delivers farmers a shed the McCahons designed. â&#x20AC;&#x153;Itâ&#x20AC;&#x2122;s a good design gold standard for mastitis detection. to ďŹ t the plant in and itâ&#x20AC;&#x2122;s underpass design allows easy access for cleaning and servicing. Itâ&#x20AC;&#x2122;s a great example of a milk harvesting facility â&#x20AC;&#x201C; modern and hygienic,â&#x20AC;? says Trevor.

One of the plantâ&#x20AC;&#x2122;s features is the LVP4500 vacuum pump. Trevor says itâ&#x20AC;&#x2122;s the heart of the operation. â&#x20AC;&#x153;This lobe pump with its variable speed drive unit, automatically alters the pumpâ&#x20AC;&#x2122;s speed to maintain a smooth and accurate vacuum level. A DeLaval VSD can reduce energy costs by between 30 and 70 per cent per cent and extend The DeLaval PR1100 60-bail rotary platform. the vacuum pumpâ&#x20AC;&#x2122;s life.â&#x20AC;?

0 0 0 0 0 0 0 $240 $270 $290 $310 $320 $340 $370 $250 $280 $300 $320 $330 $350 $380 $260 $300 $310 $330 $340 $360 $390 $270 $310 $320 $340 $360 $370 $410 $290 $320 $340 $360 $370 $390 $420

All 520mm high, H4 Pine, 45mm TG&V Options post and wire $140 on any size planter, base from $50

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Page 115

By Merle Foster

Allister and Maree McCahon’s new dairy at Te Kopuru, near Dargaville.

Hefty investment calls for hands-on approach DeLaval has a huge European history of milking machines – the product is available worldwide and is well-proven.

Allister’s family is no stranger to DeLaval plants. “This is the third DeLaval plant for our family has fitted. My father has done two.

“We elected to use DeLaval as it’s probably the simplest system – we’re happy with that because it’s basic but highly functional.”

Allister and Maree says they picked a lot of people’s brains for their new dairy. “But one of the best bits of advice we got – because we looked at all plant brands as you have too – is: ‘Pick the service and the plant comes with it’.

“So we picked the service.”

The Advance Dairy and Pump team, lead

by Noel Watkins, installed all water pipes and pumps – although it wasn’t the best time for it. Northland was in a drought during summer 2012/2013 – so everyone was singing out for water pump services.

“We had another shed on the go at the same time and just about every water pump in the district was packing up too,” says Trevor

“The washdown pump was nicely fitted and I pinched it – I needed it for another guy.”

The McCahons got a newer version for their generosity. Trevor’s team, lead by Noel, spent about 300 hours laying underfloor piping and installing pumps for vat-wash, yard-wash, two cooler pumps and all water lines, right to the backing gate.

Cell sensors

Allister and Maree installed Dairy Automation Ltd’s HerdSense herd management system, and Cellsense somatic cell sensors as one of their few extras. “It’s the bit extra we allowed ourselves above anything else.”

CellSense is mounted on the milk-line, giving accurate live Somatic Cell Counts within two minutes of cupping cows.

It works by measuring DNA released from somatic cells in milk.

DAL’s North Island sales manager Shaun Killalea says CellSense delivers farmers a gold standard for mastitis detection and is similar to a daily herd test for SCC – saving on cow

health costs and possible grades.

“It’s a great tool for management of SCC throughout the entire lactation. It is the only automated system to provide actual SCC LIVE at the bail in the world.

“CellSense is the eye of the herd management system, allowing farmers to monitor herd health instantly, meaning they can draft and treat cows from live results.”

CellSense is attached to every fourth set of cups. “It’s a laboratory grade analyser under the bails, conducting a herd test on every fourth cow, each milking. On average we get three SCCs per week on every cow,” says Allister.

Staff can monitor SCC readings to make early decisions from irregularities, and pick up infections. This sees increased profit improved cow health, especially at the end of the season, or milking OAD. “This system gives us good bang for buck, as opposed to monitoring litres and milk components. But CellSense’s real point of difference is it can be retrofitted to any make or manufacturer of plant.

“That’s massive because you don’t have to make an immediate decision on what you want, only on the plant you want.”

All data captured by CellSense goes to the DAL HerdSense system. This overall cow management system can automatically draft animals according to SCC or yield, and manages calvings, matings, heats, treatments, sold cows, deaths and drying off.

HerdSense has really impressed Maree.

“Its drafting gate is the definition of simplicity. Our cows are completely comfortable walking through.

“It’s silent – they never balk at it because the gate opens, creates a space and the cow steps into the space.”

Enjoyable enviroment

Allister says it’s a great building. “It’s important that staff can enjoy the sense of satisfaction that comes with achievement, and to create an enjoyable work environment.”

The passionate dairying couple have worked hard to build a shed they’re proud of.

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