Robotic milkers need proper consideration

A move to robotic milking has helped realign priorities and secure employment for the next generation at New Farm, Markesbury, Bath.

However, it has also highlighted the need to ensure lameness and farm set-up are adequate before making the investment.

The farm, run by brothers Andrew and Stephen Bendall, converted from a 10-point tandem parlour to two milking robots in August 2009.

As a result, previous labour problems have been solved and the 140-cow dairy now supports additional employment for Andrew’s son Richard, while giving the family more time to tackle problems holding the herd back.

Stephen says: “Before when we had the tandem parlour it started to get slow and it was difficult to get staff to do the milking routine we wanted, so we started looking at what else we could do.

“We went on various trips to Holland to see farms with robots, and once we came up with the right design, with the help of Bas Van Santen at the Dairy Group, we got Edward Lott at Kite Consulting to draw up the budgets to go to the bank manager. We then ordered the robots in February 2009, and started milking with them in August that year.”

Andrew says switching to the system has removed the “monotony” of going in twice a day and milking.

And in terms of labour savings, Stephen says: “Before we needed two people up there at milking times, but now we only need two in the morning and one in the afternoon for mucking out.”

The design incorporates an extension to the existing shed with two milking robots – one left-handed and one right-handed – on a free-access system with the cows split into two groups of mixed yielders. There are also split-access pens to enable problem cows to be separated and kept closer to the robot.

In financial terms, the robots have been budgeted to pay for themselves within 10 years, and the family expects the building extension and slatted transfer tank to be repaid within 15 years.

Two years into a robotic milking system, the family explain the pros and cons of robotic milking and what other dairy farmers need to consider before making such an investment.

New Technology

Adapting to new technology and training the cows to use a new milking system is the first hurdle when installing a robotic milker, says Andrew.

“The challenge was teaching ourselves how to work it all, and once you put this system in, someone is still tied to it,” he explains.

“For every hour the robot is down, it takes a day for the system to come right again. So if you have a problem you have to decide if you can fix it yourself or if you have to get the dealer in to fix it.”

Stephen adds: “My rule of thumb is if I can fix it in 20min I will do it, but if it’s going to take longer I get someone else in.”

Lameness

To succeed with a robotic milking system, lameness must be under control as cows with sore feet are unlikely to go and get milked of their own accord, says Andrew.

Stephen adds: “Anyone putting in a robotic milker should get a category one foot trimmer in three times a year during the year prior to converting over.

“Last year we ran into a problem with lameness, but we are getting it under control and the average yield per cow is up. We are using an independent assessor and on the last visit 77% of the herd scored 0-1 on mobility.”

And to help keep on top of problems, the farm’s computerised system “red-lists” problem cows, alerting the Bendalls of issues such as mastitis and lameness, or bulling.

Breeding

Teat position and calving pattern also need to be considered carefully when moving to robots.

The Bendalls have a herd of high-yielding cows, averaging 10,100 litres a year, with an average daily yield of 34 litres from 2.4 visits to the robot.

The family recommends breeding for cows with their back teats well apart to allow ease of use with the robotic milker. “Pay attention to back teat placement,” says Stephen.

In addition, Andrew recommends adapting your breeding system to year-round calving. “It’s better to have a group of mixed yielders because you won’t get the right capacity otherwise.”

On future plans, he says: “We might put in a third robot, but we need to get lameness and mastitis under control first before we even contemplate that.”