Managing Variable Costs on Dairy Farms Through Energy Use Assessment and Conservation

Managing Variable Costs on Dairy Farms Through Energy Use Assessment and Conservation

Acknowledgements Program Support Project supported by USDA/NIFA under Award Number 2012 49200 20032 North Central Risk Management Center Expertise and Input SDSU Extension Steve Pohl Alvaro Garcia Tracey Erickson Heidi Caroll University of Minnesota Extension Kevin Janni Jim Paulson South Dakota Dairy Producers Minnesota Milk Producers

Sponsors and Supporters Host farms, producers and staff Participants

Where is the risk? Inefficient use and management of the environmental control system can lead to Energy Use and Electricity Cost Cow Comfort and Milk Produc on

Energy Use on a Dairy Energy Consumption Considerations High Cost High Volatility Energy Use Changes Lower Carbon Footprint Economic Incentives Peterson, Richard. 2008. Energy Management for Dairy Farms. Presentation at the Farm Energy Audit Training for Field Advisors workshop. Augusta, ME. January. Innovation Center for U.S. Dairy. 2013. Stewardship and Sustainability Guide for U.S. Dairy: A Voluntary framework for tracking and communication progress. Producer Handbook. Draft.

Energy Use and Milk Production Energy Sources Feed Lighting Ventilation Feed Efficiency???? Energy Intensity Energy Used per Lb of Milk Produced

Heat Stress Energy use patterns during periods of heat stress Milking system Lighting Ventilation fan use Mixing fan use Addition of evaporative cooling

Clickers!

What percent of days is the THI above 68 in a typical Midwestern Summer? 1. 30% 2. 40% 3. 50% 4. 60% 5. 70% 6. 80% 7. 90% 0% 0% 0% 0% 0% 0% 0% 30% 40% 50% 60% 70% 80% 90%

What is the estimated economic impact of heat stress to the dairy 1. Similar to mastitis 2. Similar to reproduction 3. More than mastitis 4. More than reproduction 5. Less than mastitis or reproduction 6. More than mastitis and reproduction industry? 0% 0% 0% 0% 0% 0% Similar to mastitis Similar to reproduction More than mastitis More than reproduction Less than mastitis or reprod... More than mastitis and rep...

Brookings, SD THI Daily Averages Summer 2012 100 THImax THIavg THImin 95 90 85 80 Moderate- Severe Stress 75 70 Mid Moderate- Stress Stress Threshold 65 60 55 50 45 40 Alvaro Garcia adapted from Lance Barumguard

Workshop Outline Understanding the Impacts of Heat Stress on the Cow Understanding the Basics of the Environmental Control System Identifying and Evaluating Energy Use Changes

IMPACTS OF HEAT STRESS

Impacts of Heat Stress Incidence of Heat Stress Economics of Heat Stress Cattle Response to Heat Stress

Environmental Control System Basics Ventilation Concepts Evaporative Cooling Convective Cooling Control System

Identifying and Evaluating Energy Use Changes

Electrical Energy Used Per Lb of Milk Produced 0.06 2011 2012 2013 kwh/lb milk produced 0.05 0.04 0.03 0.02 0.01 0.00 0 20 40 60 80 100 Temperature, F

Heat Stress Management Plan Setting a baseline Observations and measurements Comparison to baseline

Summer Workshops: Evaluating Heat Stress and Energy Use on Dairies July Southwest Minnesota Late July Central Minnesota August East Central South Dakota Stay tuned for more details

How do cows respond to heat stress? A. Pant BT Resp standing B. BT Resp Pant standing C. Resp Pant standing BT D. Resp BT standing Pant E. Resp standing BT Pant 0% 0% 0% 0% 0%

Effect of THI on Behavior Activity 63.6 THI 71.6 THI 56.3 THI 73.8 THI Lying time, hr/d 8.65 a 9.12 a 10.93 b 7.91 a Standing in stall, hr/d 4.27 3.47 3.41 3.95 Standing in alley, hr/d 3.20 a 3.18 a 2.55 a 4.48 b a,,b Different super scripts are different (P<.05) Cook et al, ASABE 2007

Effects of Heat Stress on Rumination

Embryo Loss for Different THI pregnancy loss (%) 14 12 10 8 6 4 2 0 12 Summer vs. Winter: 8 3.7 times more likely to lose embryo 5.4 times more likely to lose embryo if twins (Lopez Gatius et al., 2004) 1 0 2 <55 55 59 60 64 65 69 >69 Max THI Adapted from Garcia Ispierto et al., 2006 Slide Compliments of Bilby, 2012

Total dry matter intake and pounds of dry matter required for maintenance with increasing environmental temperature (dew point = 30) 60 Pounds of Dry Matter 50 40 30 20 10 Dry Matter Intake Maintenance Req. 0 68 77 86 95 104 Temperature Holter, West, and McGilliard. 1997. Journal of Dairy Science 80:2188. Slide compliments Bilby, 2012

Higher producing cows suffer the most from heat stress 105.0 Body Temp, F 104.5 104.0 103.5 103.0 102.5 102.0 103.64 102.02 102.02 102.38 101.5 62 82 62 82 Milk Production, lb Missouri Fat Corrected MIlk Production, lb Israel Adapted from Santos, and Staples,, 2012

How about cooling dry cows?

How much does cooling dry cows increase milk production the next lactation A. None B. 0 5 lbs/cow/d C. 5 10 lbs/cow/d D. >10 lbs/c/d 0% 0% 0% 0% None 0 5 lbs/cow/d 5 10 lbs/cow/d >10 lbs/c/d

Cooling Dry Cows Increases Milk 16 lbs Cooled 46 days before expected calving Slide compliments G. Dahl Tao et al., J. Dairy Sci. 94:5976 5986

How much more do calves from cooled cows milk once they begin lactating? A. 0 lbs/cow/d B. 0 5 lbs/cow/d C. 5 10 lbs/cow/d D. >10 lbs/cow/d 0% 0% 0% 0% 0 lbs/cow/d 0 5 lbs/cow/d 5 10 lbs/cow/d >10 lbs/cow/d

Milk production from cows who were cooled or hot in utero Milk Production, lbs 80 70 60 50 40 30 20 10 0 trt: P = 0.108 CL: 68.17 lbs HT: 58.27 lbs CL HT 1 4 7 10 13 16 19 22 25 28 Week of lactation Adapted from Geoff Dahl Monteiro, A.P.A., S. Tao, I.M. Thompson, and G.E. Dahl. 2013. J. Anim. Sci. 91(Suppl. 1):184

UNDERSTANDING THE BASICS OF THE ENVIRONMENTAL CONTROL SYSTEM

Environmental System Tool Kit Exhaust Fans Source: extension.umn.edu Adjustable Controls Mixing Fans Source: uwex.edu Shade or Lighting Source: uwex.edu Evaporative Cooling Source: uwex.edu

Basic Ventilation Concepts Air exchange between inside & outside Bring in fresh air, remove excess heat and moisture 500 CFM/1250 lb cow in hot weather (MWPS 32) To have air exchange you need Inlets and outlets Something to cause air exchange Exhaust fans in tunnel and cross ventilated barns Wind in natural ventilation

Ventilation does not A. Dilute dust and gases B. Decrease the barn air temperature lower than outside C. Bring in fresh air D. Exhaust heat and moisture 0% 0% 0% 0% Dilute dust and gases Decrease the barn air te... Bring in fresh air Exhaust heat and moisture

Ventilation Systems www.milproduction.com www.milproduction.com http://www.faromor.com/english/ventilation systems/power/cross flow ventilation

Air Distribution Concepts Air distribution throughout barn Airflow pattern Uniform conditions versus dead spots? Air velocity at animal level 200 400 ft/min (1 2 m/s) to use fan output 570 800 ft/min (2.9 4.0 m/s) for humid air Air is lazy it takes the easiest path Air flows around solid obstructions

Air Velocities at High Ventilation Rate (cross flow) Velocity at Baffle 587 fpm or 6.67 mph Velocity at Inlet 350 fpm or 4 mph Airflow FA NS Cow Alley Feed Alley Feed Drive Feed Alley Cow Alley Cow Alley Feed Alley Feed Drive Feed Alley Cow Alley PA D Velocity at Feed Rail 180 fpm or 2.01 mph Air Exchange Rate for the Building 64 Seconds Source: Steve Pohl, SDSU & John F. Smith, KSU

Cooling / Mixing Fan/ Airflow Characteristics Fan output (cfm) not as important as the air velocity produced at cow level Good throw of air Maintain desired air velocity Direct air where cows should be

Evaporative Cooling Concepts Sprinkling cows Putting very fine mist into the air Using evaporative cooling pads to pre cool ventilation air Each method Has variations in practice Is conceptually different Trades sensible heat for evaporating water into the air and higher humidity

What is my priority area for cooling? A. Travel lanes B. Lactating cows C. Holding pen D. Hospital cow pen 0% 0% 0% 0% Travel lanes Lactating cows Holding pen Hospital cow pen

Control System Adjust ventilating system Fans, Inlets and Cooling equipment Make decisions and adjustments using Measured inputs (ex. temperature) and User inputs Program logic Your automated employee

IDENTIFYING AND EVALUATING ENERGY USE CHANGES

Energy Use Changes Energy Audits Identifies energy use by sector or area Most programs include alternatives Infrastructure System Components Management Practices Review of your existing system Is my system operating properly? Am I getting everything out of my current system?

Setting a Baseline Baseline measurements identify System functionality before a change occurs Means of measuring future efficiency Can take multiple forms Observations Records Measurements Write it down!

Evaluating Energy Use Changes Example Method Gather monthly milk production, energy use, and temperature data from prior year(s) Divide monthly energy use values by milk production for the same time period Plot the energy use per milk production numbers calculated previously against average temperature or THI values for the same period

Electrical Energy Used Per Lb of Milk Produced 0.06 2011 2012 2013 kwh/lb milk produced 0.05 0.04 0.03 0.02 0.01 0.00 0 20 40 60 80 100 Temperature, F

YOUR TURN

Realigning Mixing Fans Making the Change Evaluating the Change

Fan Maintenance Schedule Making the Change Evaluating the Change

Airflow Patterns Making the Change Evaluating the Change V = Q/A Shut the door

KEY POINTS

Where is the risk? Inefficient use and management of the environmental control system can lead to Energy Use and Electricity Cost Cow Comfort and Milk Produc on

Summer Workshops: Evaluating Heat Stress and Energy Use on Dairies On farm workshops Summer 2014 Will cover costs of heat stress, ventilation basics, and in barn activities to assess the environmental control system Stay tuned for more details

What energy use change are you planning to try (or recommend)? A. Fan maintenance B. Monitor bunching C. Track temperatures D. Realign mixing fans E. Monitor airflow patterns F. Review energy bills 0% 0% 0% 0% 0% 0% Fan maintenance Monitor bunching Track temperatures Realign mixing fans Monitor airflow patterns Review energy bills