Robotic milking technology making successful decisions
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Introduction Changing your milking system to robotic technology requires careful evaluation based on several factors: cost, annual running costs, capacity, reliability and service options, to mention a few. All factors are important when making this level of investment. This document has been designed to help increase your knowledge and understanding in order to aid the decision-making process when considering implementation of robotic milking technology (robots) on farm. Other terminologies used within the sector when referring to this type of parlour include Voluntary Milking Systems (VMS) or Automated Milking Systems (AMS).! Do your own, open-minded research to enable you to make a decision that is going to suit you, your family, farm staff and your herd. It is important to ascertain what you expect from robotic milking technology, in order to appraise the different systems available. Reasons for changing to robotic milking technology vary from farmer to farmer but some of the most common quoted reasons include: Enable lifestyle change For greater flexibility To solve labour and staffing problems To help address labour costs To improve animal welfare For human health reasons To keep younger generations interested To increase productivity Robots are becoming the norm.! Do not rush the decision-making process, many current robotic milking machine users have taken a number of years before committing. Take your time and make the right decision. Speak to a selection of suppliers. Be aware that prices will vary depending on the specification of machine you require, therefore ensuring like-for-like quotes from the start is important There are a number of key questions that may help when speaking to suppliers: Will you provide guidance for best housing design, cow flow and location of the machine? Will you provide nutritional advice from a qualified individual? 3
Are these services included in the quoted costs or additional? Who will be my direct line of contact? You may have the option of buying direct from the main manufacturer or from a local stockist, commonly known as a dealer Who will install the equipment? What will happen if the robot stops working? What other problems might I expect? How much downtime there will be with the robot, for cleaning, etc? What back-up support will I receive how quickly will problems be dealt with? Be prepared to stand your ground sales personnel will be keen to get a sale Visit other farmers who have already installed robotic milking technology what better independent advice can you get than first-hand from a like-minded farmer. Most farmers will be willing to share their experiences good and bad Many producers justify a visit to sites abroad. Commercial use of robotic milking in other countries such as Germany and Sweden is somewhat more of a common practice than in the UK Speak to your milk buyer they should provide guidance and support.! Consider all options with an open mind. There are no hard and fast rules about which robot to choose, it s about working out what works best for you. 4
Other practical questions to ask yourself... Am I in the right financial position to make the transition? Investment levels will vary significantly depending on individual farm set-up. Unit cost will vary between manufacturers it is important to assess what value you are getting for your money and if you feel it is the right investment. As with any investment, do cost comparisons of different systems to ensure the level of investment is right for your business plan Purchasing units in multiples may allow some discount on the guideline price it is worth asking Consider installing second-hand units; however, it is important to ascertain whether quality checks have been carried out and agree whether a service and maintenance agreement can be provided Ensure you cost out all aspects of the build and capital investment Consider the payback periods for the investment and business plans over the same time period. i Make use of partial budgets and tools such as DairyCo Dairy Wizard to aid with costing out the changes. Factor in all costs when considering installing robotic milking machines, for example, we had to upgrade our electric supply. Will I face increased production costs? This depends on the size of your current herd and the cost of your labour, cost of production (pence per litre) can compare favourably to parlour milking in 60-180 cow herds. Some elements of production costs may increase with the change of system while others may reduce. Calculate the cost of production using your current system to enable an accurate comparison The pattern of electricity use may differ as water heating and milk cooling requirements are constant rather than for set time periods. Investigating ways to make best use of different energy efficiency techniques and charging periods may offset this increase Changes to feeding systems may have an impact on production feed costs Consider your labour costs time spent carrying out milking-related tasks will be somewhat reduced, however, stock tasks will still need to be carried out. Savings are likely to be possible if the total labour use is reduced. 5
i Having a comprehensive view of current cost of production and the elements which make up these is important to help you understand the potential differences that a change of system can make Milkbench+ is one service that can help with this. I don t spend any less time working on the farm but I m spending my time differently managing and really using my stockmanship skills, it s a case of getting used to the robotic system and managing your cows within it. Robots don t cut down the amount of work, it entails the same hours but I feel better and stress free. How many milking units will I need? The optimum number of cows which the robot can milk will vary between manufacturer and model. As a guideline, this number usually ranges between 60-70 cows in milk per unit Some manufacturers may base the number of milking units required on the volume of milk collected in a 24-hour period, rather than the number of cows milked Consider how your calving pattern may affect the volume of milk produced seasonally Take account of any expansion plans you may have for the future. Although this may cost more at the outset, plans for expansion need to be considered pre-purchase rather than after installation when expansion options are likely to become more limited or costly. Can my existing building accommodate robotic milking or do I need a new building? Most existing buildings can be adapted to accommodate robotic milking machines, however, it is likely that some modifications will be required. You need to think about the layout of your farm and what suits your labour and family situation. Ask the manufacturers what space requirement and, thus, changes may be required and how best to approach these, it is likely that they will be able to come and look at your existing set-up and provide individual advice based around your requirements. Consider what kind of cow flow approach would best suit both your herd and your building layout. There are two main types of cow traffic: Free cow traffic allows the cows to travel anywhere in the building unimpeded and have free access to feeding, resting and/or milking at all times. Feed within the milking unit motivates cows 6
to visit the milking unit (Fig 1). Other terminologies used within the sector when referring to this type of cow flow system may include open access and free flow Guided cow traffic is such that a series of one-way gates guide cows through the robot when they move between resting and feeding areas. Another option with guided traffic is when there are pre-selection gates which select cows that are ready for milking while on their way to the feeding area; cows which are not ready for milking proceed to the feeding area (Fig 2). Other terminologies used within the sector when referring to this type of cow flow system may include channelled traffic. Feeding area Milking unit Automated gates Cow traffic Cow ID tag sensor Milking units Cow traffic Feeding area Feeding area One-way gate Fig 1: An example of a building design using free cow traffic Fig 2: An example of a building design using guided cow traffic Consider whether your current electricity supply will be adequate; single phase electric may be limiting It is your responsibility to ensure any building modifications adhere to legal requirements or stipulations made by your milk buyer. i If adapting existing buildings, ensure that this does not compromise the stocking density and ensures that adequate loafing area is still provided. Does the siting of and layout around the robot matter? It is extremely important to get the layout and design correct from the start well functioning cow flow is an important part of successful robotic milking, take time over planning this. The system of cow flow you decide on will have a bearing on the siting of the robots Listen to the experience of others get advice from manufacturers Some cows are likely to have to wait to be milked for short periods of time in close proximity to the robot, rubber matted slatted areas within the waiting area may work well to avoid slurry pooling and also be kinder on cows feet than standing on concrete Consider the positioning of the robot in each yard. If cows are moving between areas throughout lactation, ensure that cow flow into the unit is always in the same direction, ie always from the left or from the right Robots should be sited so they are easily visible to cows 7
Ensure adequate lighting is provided Consideration should be given with regard to the siting of the robot in relation to the dairy, bulk tank and main electricity supply to the building Consider the location of the robot in relation to the calving pen. i Information on legislation, building design and cow flow can be found in the DairyCo resource Dairy Housing a best practice guide. How will I deal with technical problems (breakdowns)? The level of support will vary between suppliers, it is important to ascertain the level of support you are going to receive during and post installation in the event of problems occurring. Ensure you have an agreed back-up plan How quickly will problems be dealt with? Ascertain whether buying from a local dealer compared to direct from manufacturer will have positive or negative effects on your level of support Local dealers may take longer to respond to system issues due to lack of technical knowledge, on the other hand, they may be in closer proximity than manufacturers and be able to deal with minor problems quicker Ensure you have an agreed maintenance plan within your contract. Use a company that will provide you the level of support required and with the best back-up plan. Are my computer and technology skills adequate? The information technology world is ever advancing, and keeping up to speed can be somewhat of a concern for some. Robotic milking machines are an example of how technology is advancing and requires an understanding of computer systems. Ensure that you choose to work with a supplier who will provide you with the support that you require You need to ensure that the computer system can be fully understood by at least one member of the family/member of staff, lack of understanding can have detrimental long-term effects on the herd If you have concerns about your competence level, gaining some experience on other farms already using robotic milking machines may help There is a strong element of using the output from the machine for routine herd management tasks, therefore, it is key that IT skills to interpret this information are available Training programmes may be available from some suppliers on both skills. 8
Can I still give my cows access to grazing? This is a question/concern that is often raised when people are considering moving to robotic milking technology. Robotic milking technology does allow a system to be developed which combines automated milking with optimal grazing. Free or guided cow traffic flow can be applied during the grazing period, ascertain what will suit your system best Carefully consider what grazing gate technology is required. One-way gates at the building entrance and selection gates at the exit to pasture can be useful to control cow flow Cow flow is of even greater importance when cows have access to grazing areas. Consider the distance between the robotic milking machine and the furthest point of grazing, is it an acceptable distance for cows to walk? Expect that, as being herd animals, cows will often return to buildings in groups or in close succession a number of animals may return to be milked at the same time, hence incurring a waiting time. How will robotic milking affect my feeding system? The provision of feed in the robotic milking unit is one of the factors that motivates cows to visit the robot for milking. For herds using a Total Mixed Ration (TMR) approach to feeding, some adjustments may be required, there are ways in which you can adapt your feeding regimes. Very palatable ingredients fed in the robot may encourage good cow flow. Ascertain whether there is a possibility of individual feeding regimes for individual cows Be aware that individual cow s productivity may change when moving to a robotic milking system, this will require monitoring and adjustment accordingly Determine what equipment will be required if a different/additional feeding system is required and how much this will cost to install Ensure that any nutritional advice you receive is from someone that is experienced with robotic milking units. Will my cows take to a robotic milking system? The cows got used to it much quicker than we did has been quoted by a number of current robotic milking machine users. Typically, when an existing herd is switched to robotic milking it takes 3-4 weeks of encouraging a high number of cows on a daily basis and, by three months, the majority of cows use the system voluntarily. The robotic milking machine has meant we have a much better idea of how many good cows we have and which ones they are. The system allows cows to reach their potential. Put a plan in place to introduce cows to the new equipment this will help keep stress levels (both animal and human) to a minimum 9
Assess the health of your cows, they need to be in good health with good mobility, as visiting the milking units relies on voluntary movement Is your somatic cell count at a suitable level? It is not uncommon for cell counts to rise slightly when first using robotic milking technology. Ensure that any changes to your cell count will not affect your milk contract Consider the age of cows within your herd younger cows and more aggressive cows tend to adapt more easily Heifers may need individual attention for a couple of days to assist with teat location You may have to fetch some cows for milking the number of cows will depend on what you perceive to be an acceptable time lapse between each milking and the system design. i Herd health is always important therefore routine mobility scoring and body condition scoring can help identify any changes in the individual cow s health. Information on both processes and resources can be found on the DairyCo website. Allow yourself time to get used to the change in system, there is a lot of learning to do both about the system itself and the changes to cow behaviour. Will I have to cull many cows? This will be dependent on the individual cows within your herd; it is not uncommon to have to cull a small proportion, due to being unsuitable for robotic milking. This has typically been found to be 0-3%. Reasons for culling include: Udder conformation Teat placement (2 very close teats may be seen by the sensors as one teat) Cows with extreme rear udder attachment where the rear teats are much higher than the front teats Very high or low udders Some producers have found that lasers may find locating black teats more difficult Cows not adapting to robotic milking units Cows becoming aggressive towards the unit i Keeping records of the reasons cows leave the herd can help with understanding if there are any elements of the system which need attention reasons for voluntary and involuntary culling are covered in the resource Managing herd replacements 10
Further information As with all technology, that of automated milking is constantly advancing, this includes research into both the technology behind the machines and the management of the herd in-line. As the GB dairy levy body, DairyCo is looking to ensure this latest information is fed back to GB producers via its numerous communication channels however, should you require any further information in the short term, please contact your local extension officer, contact details can be found on the DairyCo website www.dairyco.org.uk While the Agriculture and Horticulture Development Board, operating through its DairyCo division, seeks to ensure that the information contained within this document is accurate at the time of printing, no warranty is given in respect thereof and, to the maximum extent permitted by law, the Agriculture and Horticulture Development Board accepts no liability for loss, damage or injury howsoever caused (including that caused by negligence) or suffered directly or indirectly in relation to information and opinions contained in or omitted from this document. Agriculture and Horticulture Development Board 2013. No part of this publication may be reproduced in any material form (including by photocopy or storage in any medium by electronic means) or any copy or adaptation stored, published or distributed (by physical, electronic or other means) without the prior permission in writing of the Agriculture and Horticulture Development Board, other than by reproduction in an unmodified form for the sole purpose of use as an information resource when DairyCo is clearly acknowledged as the source, or in accordance with the provisions of the Copyright, Designs and Patents Act 1988. All rights reserved. AHDB is a registered trademark of the Agriculture and Horticulture Development Board. DairyCo is a registered trademark of the Agriculture and Horticulture Development Board, for use by its DairyCo division. All other trademarks, logos and brand names contained in this publication are the trademarks of their respective holders. No rights are granted without the prior written permission of the relevant owners. 11
Agriculture and Horticulture Development Board Stoneleigh Park Kenilworth Warwickshire CV8 2TL T: 024 7669 2051 E: info@dairyco.ahdb.org.uk www.dairyco.org.uk DairyCo is a division of the Agriculture and Horticulture Development Board