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Transitioning from conventional to robotic milking is a critical process that can be successfully executed as long as you plan your work and work your plan. It requires consistent work and methodic execution.
Avoiding negative impacts on people and cows by preventing undesirable events is crucial. Applying these principles enables the possibility of enjoying the features and benefits of this
fantastic technology.
Not every dairy begins the transition process from the same starting point. Today, approximately 60 percent of automatic milking system installations are constructed new and 40 percent are retrofitted, where cows remain in the same environment before and after startup. Both scenarios are different and require diverse transition management strategies.
New facilities can have a greater impact on the herd during the transition period due to major environmental changes. A strategy to ease the transition into new facilities can be as simple as
housing the animals in the new barn while continuing to milk in the conventional parlour. From every angle, gradually transitioning the cows is key to the smoothest adaptation.
Due to lower stress levels surrounding familiar environments, retrofitted installations have a lower impact on milk production and cow behaviour after startup.
The transition period covers three phases: six months before startup, startup and six months after startup.
In this article, we will focus on the first phase: six months prior to startup. This is the most important phase from all perspectives. It is the time where all plans and strategies must be de fined. Unfortunately, this step is often underestimated. Ignoring crucial details and decision-making associated with startup planning will result in undue stress and a potential delayed transition.
Six months before startup
EDUCATE THE WORKFORCE
No doubt – moving into robotics requires additional skills concerning technology and herd management. Recognizing weaknesses and strengths within the management team is key in order to prepare ourselves for the new challenge.
GET COMFORTABLE WITH COMPUTERS
If you have already been working with herd management software, then you are probably ready. However, if instead you have had little or no contact with computers, now is the time to get back to school and take some classes. It does not mean that you need to become a computer expert; it means it is time to learn the basics. Experience will come with practice and time.
IMMERSION IN THE WORLD OF ROBOTIC MILKING
Touring and visiting dairies is a common practice for farmers interested in robotics. In order to learn how to run successful robotic milking operations and benchmark your success, one of the key objectives must be to build a network of peers. In addition to traditional learning opportunities, including reading materials or attending meetings, there are more innovative education channels such as webinars, virtual libraries and, of course, the social media community. Make sure to do your homework by using multiple learning strategies and inviting the entire farm team members including external advisers.
Two months before startup: Set the herd
This is the time to put all the focus and effort on the herd.
HOW TO SELECT THE RIGHT ANIMALS
There are three main criteria to consider when selecting cows for a robotic milking system: udder conformation, udder health, and feet and legs. In robotic milking every second counts, and being able to attach rapidly and accurately is necessary for both cow health and system performance. Select cows with centrally placed teats and avoid rear-crossed teats. Finding a balance between teat placement and udder cleft will have a positive impact on cow longevity.
If there is a possibility to select animals from a larger group, consider the following five-step selection process in order to have an ideal group of “robotic” cows:
- Identify the animals with highest milk flow rates.
- Out of that group, test and select the individuals that have low somatic cell counts and are negative to contagious mastitis pathogens.
- Evaluate udder conformation, especially rear teat placement.
- Make sure cows have good, healthy feet and legs.
- If possible, group cows based on lactation number. Dedicated young and mature groups are ideal.
EVALUATE YOUR CONTAGIOUS MASTITIS SCREENING PROGRAM
Once the final group of cows is de fined, the main objective is to ensure every animal entering and being milked by the robot is free of contagious pathogens. Unfortunately, due to group management and dynamics, segregation of infected cows is not a viable option in robotic milking systems compared to conventional milking systems. It is strongly recommended to run monthly bulk tank cultures and monitor cows individually.
Culture all cows above 200,000 SCC for more than one week, every other day. If a cow has at least one sample positive to pathogens such as staph. aureus, she is considered positive and a decision has to be made. Your veterinarian’s involvement is critical to develop a milk quality plan.
CONSIDER HOOF TRIMMING NOW
All cows should visit the hoof trimmer between one and two months prior to startup in addition to receiving consistent footbath treatment. Do not wait until the last moment to trim feet, as the combination of new concrete, stress factors and trimming procedures can lead to undesirable hoof issues.
REVIEW THE DESIGN OF YOUR SOPS WITH KEY PLAYERS
Planning by scenarios and consistency are two special bene fits of robotic milking. The best way to capitalize on both is through aligning the team, including the herd veterinarian and nutritionist. The objective is to develop, discuss and apply the set of herd SOPs moving forward.
20 days before startup: Get everyone ready
REMOVE UDDER HAIR
Udder hair removal is a must with robotic milking systems. Cows should be enrolled in a two-month or three-month schedule, varying by season. In order to efficiently perform udder hair removal, it is strongly recommended to make this a weekly or biweekly routine. Working with smaller groups of cows avoids major disruptions.
ACCURATELY TRANSFER YOUR DATA
Take time to transfer data or build the new database well in advance of starting up. Remember, the quality of entered data is equal to the quality of obtained information. Try to maximize software usage from the beginning.
DEVELOP YOUR FEEDING PLAN DURING THE TRAINING PERIOD
Although not every installation is able to have a feed-only period, it is highly recommended and ideal to feed cows through the robot (not milking) at least two weeks prior to the first milking. Feeding before is probably the best practice with the highest impact on early performance after startup. Keep in mind, it is important to ensure feed consistency by avoiding provider and formulation changes during this period of time. The amount to feed varies depending on cow traf fic and day of transition, ranging between .9 to 3.6 kilograms per cow per day.
After one week, it is possible to combine feeding only with spraying teats and robotic arm movements. Combining the two will motivate cows to visit the robot and acclimate them to the new sounds and environment.
Although feed-only has the biggest impact on early performance, it is not the only method to train cows. There are other techniques that depend primarily on cow traf fic design. Ask your provider for advice on this topic.
BEGIN YOUR STARTUP ON DEFAULT SETTINGS
The entire system must be in “safe mode” in preparation for startup, from milking procedure to feeding, and general management settings. If settings are placed with maximum levels of protection for your herd, the focus can turn to proper herd management basics including clean bedding, frequent feeding and push-up, and training/fetching of overdue and new cows.
Two days before startup: Almost there
Now is the time to make sure all components of the robotic milking equipment and systems are working properly and that the cows and people are aligned. The entire project must be organized for final inspection and evaluation. These are the top five points to consider:
- System evaluation
- Regulatory inspection
- Database surveillance
- Proper animal identi fication
- Coordinated startup teams and schedule
By turning the above transition plan from conventional to robotic milking into a reality, and always remembering the focus on team communication for optimal success, you should be ready to go for this exciting journey. Through planning your work and working your plan, you can anticipate good news and great results.
Once the robots are fired up and the real journey has begun, it is time to focus on the right areas by planning for a bright future. Keep in mind that with a good plan in place, the sky can be the limit.
Two days post-startup: Focus on the basics and keep it simple
The beginning is the most difficult part of any change. By now both you and the cows are in the steadiest part of the learning curve. You have acquired a very capable piece of technology and, as expected, you may feel very attracted by it. However, it is crucial to prioritize your efforts in order to have the smoothest transition by focusing on the fundamentals. It is important to ensure the entire system is configured at a baseline where each area can function without major adjustments or in what is called a “safe mode.” Beginning in safe mode enables you to focus on daily routines and, most importantly, herd adaptation. In other words, you organized a big party, you invited the girls, and now you must be the best hostess:
1. Milking intervals and milk frequency:
The goal by the end of the first week is greater than 2.5 milkings per cow per day with a minimum of two milkings per cow per day for all animals. In order to ensure milking intervals under 12 hours and an appropriate balance between milk frequency and robot usage, it is important to set adequate milking permissions based on stage of lactation:
• One to 100 days in milk (DIM): four hours or 14 pounds expected yield
• 100 DIM until 40 days before dryoff: six hours or 16 pounds expected yield
• Less than 40 days before dry-off: eight hours or 18 pounds expected yield
Remember, with guided cow traffic it is essential to ensure proper smart selection gate configurations and holding area management by setting cow counters and maximum capacity based on area per cow and robots per holding pen. Ideally, cows should have 45 square feet per cow in the holding area and no more than seven cows allowed per robot. The goal is to harvest 30 pounds per milking, and although these milking permissions parameters seem to be much lower than listed, remember that cows will not have access to the robot at every single attempt, as it might be in use or a group of cows are already queuing, etc. Therefore, adding flexibility in the beginning is important.
2. Fetching:
Due to the learning process, and based on your milking queue reports, it is important to guide overdue cows (more than 12 hours since last milking) to the robot. A gradual process must be implemented based on how fast the herd is adapting to new cow flow. Start fetching overdue cows every four hours, then as cows learn and number of overdue animals start decreasing, the fetching intervals can be extended to every six hours, then eight hours, up to the point where fetching occurs every 12 hours or just twice a day.
3. Milking procedure:
Make sure the entire tool kit is being used in order to protect udder health at all times:
• Use compatible/sprayable teat dips.
• Maximize teat coverage through appropriate nozzle size, spray pattern, proper indexing of cows and arm speed.
• Pre-milking and post-milking spraying of teats with an effective disinfectant is highly recommended.
• Use of an approved disinfectant diluted accordingly for teat cleaning is necessary.
• Set the system for heavy teat cleaning level regardless of bedding system or surface cleanliness. This way your cows will be at maximum level of protection.
4. Feeding:
The main objective is to motivate cows in order to maximize visit frequency to the robot at all stages of lactation so consistent cow flow patterns are developed and fetch rates are minimized. Cows must always have feed available at the feed bunk, meaning feed cows at least twice per day ensuring frequent push-ups, at least every four hours. Concerning feed at the robot, an adequate baseline for feeding parameters is necessary:
• Feed available per cow per day: Depending on the kind of cow traffic scenario, levels of grain must vary. In order to keep it simple so you can focus on the fundamentals, a basic but safe feeding strategy must be in place. Set a fixed amount of feed available per day and per visit for all cows so the entire herd is equally motivated. This is a recommended strategy for the first 20 days post-startup only.
• Free-flow or feed-first pre-selection: 16 pounds per cow per day available for all cows, 4 pounds per visit.
• Milk-first pre-selection: 8 pounds per cow per day available for all cows, 2 pounds per visit
As expected, feed consumption will vary according to milk frequency; therefore, partial mixed rations
(PMR) should be balanced during this period according to the average feed consumed per day reported by the system.
5. Bedding management:
As this is a stressful period for the cows and the udder is adapting to the new system, clean stalls and a dry, comfortable bedding surface must be provided at all times. Clean alleys are necessary as well.
6. Data management:
At this point, you should be able to manage action and key performance reports with a very simple approach, focusing on daily tasks and making sure the herd is moving in the right direction. Screening of essential reports three times a day is enough. Avoid fine tuning and frequent adjustments during this period.
20 days post-startup: Time to evaluate and adjust
Once the most stressful period has occurred and both cows and people are adjusting to their new lifestyle, it is time to evaluate and start adjusting the system:
1. Feeding:
Based on cow traffic, feeding strategies, feeding quantities, days in milk, milk frequency and milk production, implementing a customized feeding plan for the operation is highly recommended, considering the three feeding phases of feeding in robotics:
• Adaptation: zero DIM until 15 to 21 DIM
• Target: 15 to 21 DIM until 70 to 100 DIM
• Optimization: greater than 70 to 100 DIM
Once the feeding plan is designed and reviewed by the management team, including advisers, then the next step is to configure the system. Make sure you have appropriate understanding of the different settings and parameters; otherwise, consult you equipment provider. Last but not least, ensure that individual feed consumption at the robot is higher than 80 to 90 percent on 72 hours average; if some animals are less, then troubleshooting is necessary.
2. Fetching:
Now that the majority of the cows are visiting the robot on their own, it is time to evaluate fetch rates and fetching times, and therefore, adjust routines if necessary. The key aspect at this time is to start prioritizing fetching based on stage of lactation. Milking intervals in fresh cows shouldn’t be higher than eight hours, while mid-lactation and late-lactation cows can continue with 12 hours.
3. Evaluate milking performance:
Identify animals presenting difficulties while attaching or milking, as there are several factors that can interfere with appropriate performance, especially the ones related to udder conformation, teat shape, animal temperament or even udder cleanliness. It is recommended to evaluate the performance index per cow. Ideally, you would like to have the entire herd above 100, which means an attachment time of less than 15 seconds per teat or one minute total. Focus on the animals that are below that threshold, prioritizing the ones in the lowest part of the range.
4. Milk quality and udder health:
Daily screening of udder health indicators is crucial; ensure proper report design and management routines. Regardless of the technology, udder health must be a priority, especially as your physical contact with the herd is probably less than before. Animals with abnormal indicators must receive a physical exam so actions such as culturing can be made on time.
5. Data management:
Now is the time to get more involved in system configuration and details, especially in two key areas: milking procedure and feeding management. Assessing and measuring become a very important part of your daily routines.
Two months post-startup: Fine-tuning for maximum performance
Now that the herd has settled, people have learned, and the entire system is hungry for improved performance, it is time to start exploring new opportunities:
- Feeding: Fine-tune dispensing rates at group level and dispensing speed at cow level. This will ensure that cows receive what they deserve while enjoying their milking; this has a positive impact on letdown and therefore milking speed.
- Stall times and robot performance.
- It is recommended to stop dispensing feed when only two quarters are being milked, as this will ensure that by the time the milk flow ends, the cow has no feed left in the feed bowl; therefore, leaving the station for the next cow is the only option.
- Evaluate yield per milking individually and adjust milking permissions at group level or cow level if necessary; this will optimize robot usage.
- Evaluate udder health and teat cleaning parameters so teat cleaning level can be adjusted. Getting clean cows to the robot pays; less cleaning times equals more available milking times.
- Breeding: Ensure proper configuration of activity systems and breeding reports; now is the time to leverage other sides of the technology in order to improve crucial areas such as reproduction.
Six months post-startup: Setting your goals en route to success
It is time for strategic planning based on scenarios and time tables. Setting short-term, mid-term and long-term goals and actions will drive your herd to the stage you have always desired; keep up with the great work and good luck!
Source: DeLaval
