Archive for precision feed management

£10,000 a Month in the Red: Why UK Dairy Margins Collapsed – And What’s Actually Working

When processor profits climb while your milk check drops, it’s not a coincidence. It’s a message. And once you understand what that message is telling you about how the modern dairy supply chain works, you can stop second-guessing yourself and start making strategic decisions.

Executive Summary: A 200-cow UK dairy loses roughly £10,000 every month when milk price sits 8-10ppl below cost of production. Right now, that describes most operations. AHDB’s April 2025 data shows just 7,040 producers remaining in Great Britain—down 2.6% in a single year—while First Milk’s operating profit climbed 22% to £20.5 million. Retail discounters now command nearly 20% of UK grocery spend, and post-Brexit policy lacks the milk-specific safety nets that cushioned the 2015-2016 crisis. This isn’t farm failure. It’s market structure. Three approaches are delivering real results for producers fighting to stay viable: strategic culling of the bottom 15% of the herd, precision feed management with qualified nutritionist support, and capturing beef-cross calf premiums through targeted breeding. Combined, these strategies can reduce monthly losses by £7,000-8,000—buying time to explore processor alternatives and the collective engagement approaches already producing results in Ireland.

UK dairy margin pressure

I’ve been talking with UK dairy farmers a lot lately, and you know what keeps coming up? This quiet worry that maybe they’re just not good enough at this anymore. That somehow the losses they’re seeing reflect something they’re doing wrong.

Here’s what I want to say to that: if you’re running a technically sound operation—decent yields, reasonable cell counts, professional management—and you’re still hemorrhaging money, that’s not farm failure. That’s market structure. And there’s a real difference between those two things.

Let me walk you through what I’m seeing.

The Numbers Behind the Frustration

So let’s start with the processor side, because that’s where this story begins.

First Milk’s Annual Financial and Impact Report for the year ending March 2025 shows turnover of roughly £570 million and operating profit around £20.5 million—up from £16.8 million the previous year. That works out to an operating margin just over 3.5%. The cooperative points to higher product volumes and the full integration of BV Dairy as key drivers.


Metric
2023/242024/25Change
First Milk Operating Profit£16.8 million£20.5 million+22% ↑
First Milk Operating Margin~3.2%~3.6%+0.4pp ↑
GB Dairy Producers~7,2407,040-2.6% ↓
Farms Exitedn/a~200-200 farms ↓

Meanwhile, AHDB’s producer numbers survey from April 2025 shows we’re down to about 7,040 dairy producers in Great Britain. That’s around 160 fewer than the previous survey in October, and nearly 200 fewer than a year ago—a 2.6% annual decline. The exits tend to cluster ahead of winter housing, which makes sense when you think about the capital and workload involved in bringing cows inside.

Here’s what’s interesting, though. Even as farm numbers drop, total milk production keeps climbing. AHDB data shows the GB milking herd continuing its gradual decline, but litres per farm keep rising. Fewer farms, bigger herds, more milk per unit. That pattern’s been consistent for decades now.

And the cost picture? The Dairy Group’s September 2024 newsletter pegs the UK cost of production for 2023/24 at around 45 ppl, with their forecast for 2024/25 at approximately 44.2 ppl. Their analysis suggests it’s “extremely unlikely” we’ll see costs drop back below 40 ppl anytime soon.

So when farmgate prices sit in the mid-30s and the cost of production hovers in the mid-40s, you’ve got a gap of roughly 8-10 ppl. For a 200-cow herd producing about 1.5 million litres annually, that works out to something like £120,000 a year—close to £10,000 a month just to stand still.

The £10,000 gap that’s killing UK dairy farms isn’t about bad management—it’s about market structure.

Now, every farm pencils out differently. But consultants I’ve spoken with say these kinds of numbers line up pretty closely with what they’re seeing in real accounts.

Why This Cycle Feels Different

If you’ve been farming through previous downturns, you’re probably thinking about 2015-2016 right now. Similar oversupply pressures, similar price corrections. But something feels different this time, and I think that instinct is worth exploring.

During the 2015-2016 crisis, Brussels stepped in with a €150 million EU-wide scheme—created through Delegated Regulation 2016/1612—that paid farmers voluntarily to reduce milk deliveries for a few months. According to the European Court of Auditors’ special report on the EU’s response to the milk market disturbances, aid was set at €14 per 100 kg of milk to reduce deliveries by around 1.1 million tonnes. It wasn’t a perfect solution, but it was something.

Since leaving the EU, the UK hasn’t had a like-for-like replacement for that specific tool. Support has tended to come through broader environmental schemes and general farm payments rather than milk-specific production incentives. When processors announce cuts today, there’s less cushion. And it’s worth noting that devolved agricultural policies mean Scottish and Welsh producers face different support landscapes than those in England—something that adds another layer of complexity when comparing notes with neighbours across borders.

The retail landscape has shifted, too. Kantar’s December 2025 grocery data shows Aldi holding about 10.5% of the UK market and Lidl at 8.1%. Together, discounters now account for close to a fifth of all grocery sales—up from around 13.6% just five years ago. That buying power inevitably influences how hard they push wholesale prices, including dairy prices. It’s not that traditional supermarkets don’t care about farmgate sustainability—many genuinely do—but it’s harder to hold that line when your competitors are focused purely on cost.

And then there’s the processor balance sheet question. First Milk and others have taken on debt for capacity investments and acquisitions. When leverage ratios are around 3x and debt service coverage needs to be protected, there’s real pressure to maintain margins. I don’t think farmers should dismiss these constraints as excuses—they’re genuine business realities that boards have to navigate.

What producers are discovering is that the support architecture from the last major crisis has changed. Understanding that helps you think more clearly about your options.

Three Approaches That Are Actually Working

Understanding the market is useful, but you need actionable steps. I’ve been tracking what’s delivering results for farms navigating this environment, and three approaches keep coming up in the operations that are extending their runway.

Taking a Hard Look at the Herd

Here’s something that sounds counterintuitive but makes good financial sense: thoughtful culling can improve your monthly position even while reducing production.

You probably know this already, but the bottom 15% of most herds—cows with persistent cell counts above 400,000, yields consistently below 20 litres daily, or chronic fertility challenges—consume similar feed, labour, and veterinary resources as top performers while generating less revenue meaningfully. We’ve understood this principle for years, but current market conditions make acting on it more urgent.

I recently spoke with a consultant who walked through the numbers with a 200-cow client in northern England. They identified about 30 chronically under-performing cows—high cell counts, repeated fertility issues, cows that had been given plenty of chances—and sold them into a solid cull market at roughly £650 a head. That brought in close to £20,000 in cash.

Financial ComponentCalculation (200-cow herd)Impact
Bottom 15% Identified30 chronically under-performing cowsHigh SCC, low yield, poor fertility
Immediate Cull Revenue30 cows × £650/head£19,500 cash
Monthly Feed SavingsReduced ration costs + supplements£2,000-3,000/month
Annual Feed Savings£2,500/month × 12 months£24,000-36,000/year
Total Year 1 Financial ImpactCash + savings£43,500-55,500

Source: Consultant case study, northern England; cull market pricing autumn 2025

More importantly, the farm cut its monthly feed bill by several thousand pounds and saw modest savings in vet and labour costs. The net effect moved them from a deeply negative monthly position to a more manageable one.

While every herd pencils out differently depending on your system, your cull market, and your costs, these are the kinds of numbers many accountants are now working through with clients. The key is being honest about which animals are genuinely contributing and which are just consuming resources. Work with your vet to ensure culling decisions account for your calving pattern and transition cow management—you don’t want to create gaps in your fresh cow pipeline that cause problems six months down the road.

With December and January typically being strong months for cull cow demand—processors need to fill orders before spring, and the beef trade tends to hold up well through winter—the timing for these decisions is actually reasonable right now.

Getting Smarter on Feed

Feed typically represents 40-60% of production costs, so even modest improvements here compound meaningfully. Two levers deserve attention, and they work well together.

The first involves precision nutrition. Advisers from groups like The Dairy Group and Kingshay regularly highlight the gap between typical and efficient operations on concentrate use—sometimes 0.50 kg per litre versus 0.41 kg per litre. That gap represents real money over the course of a lactation.

But here’s the thing—and I can’t stress this enough—closing that gap requires proper involvement from a nutritionist. Cut too aggressively without professional guidance, and you risk losing more in butterfat and protein performance than you save on inputs. I’ve seen farms try to do this on their own and end up worse off because yields or components drop. Get someone qualified involved before you change rations.

The second lever is collective purchasing. Advisers from Kingshay and The Dairy Group report that members of their buying groups can often secure noticeably better prices on straights and blends than lone buyers—sometimes shaving several pounds per tonne off the ticket price. The exact savings vary by region and by what you’re buying, but across a winter, those differences add up.

What’s encouraging is that I’m hearing about more farms in the Southwest and Midlands joining these groups this autumn. The administrative overhead is minimal, and the buying power is real.

Finding Revenue on the Margins

This is where farms can add income without major capital requirements.

In current UK auctions, it’s not unusual to see well-bred beef-cross dairy calves selling for several times the value of plain dairy bull calves. One recent market report from the South of England showed continental-cross calves comfortably into the low hundreds of pounds, while plain dairy bulls lingered at much lower values. Using sexed beef semen on cows not needed for herd replacement is a straightforward way to capture some of that premium.

Calf TypeTypical Market ValueAnnual Calves (200-cow herd)Annual RevenuePremium vs Dairy Bull
Plain Dairy Bull£20-4050£1,000-2,000Baseline
Beef-Cross (Continental)£100-15050£5,000-7,500+£4,000-5,500
Your OpportunitySwitch 40-50 calves40-50+£3,200-6,000£80-120 per calf

For a 200-cow operation with flexibility on breeding decisions for 100-plus females, targeting 40-50 beef crosses annually can add meaningful revenue without changing much else about your system.

The contracting opportunity also deserves a look. The NAAC Contracting Prices Survey for 2024-25 puts typical charges for slurry spreading with a tanker and trailing shoe at around £75 per hour, with forage harvesting operations ranging from £83 to over £200 per acre depending on the service level. For a farm with decent machinery and some spare labour capacity, doing a modest amount of contract work for neighbours can turn idle time into a few hundred pounds a month during peak seasons.

Neither of these is transformative on its own. But combined with the herd and feed work, they add up to something that can make the difference between a sustainable position and a forced exit.

44-45 ppl
Your real cost of production
According to The Dairy Group's September 2024 analysis, this is where UK operations sit today. If your milk check is in the mid-30s, you're underwater before you start.
7,040
Dairy producers remaining in Great Britain
AHDB's April 2025 survey count. That's 2.6% fewer than a year ago. The exits are accelerating, and they're concentrated in winter—right now.
£10,000/month
What a 200-cow herd loses when prices sit 8-10 ppl below cost
That's £120,000 a year just to stand still. This is the gap farms are trying to close with the strategies in this article.

The Combined Picture

When I model all three approaches together—strategic culling, feed optimisation, and revenue diversification—the financial shift becomes meaningful.

For a 200-cow operation starting at roughly £10,000 monthly losses, you might get that down to £2,000-3,000 monthly through these changes, plus a one-time cash injection from the cull animals. For larger 500-cow operations, the numbers scale accordingly.

From crisis to breathing room in three strategic moves. This waterfall chart shows the actual financial trajectory when UK dairy farms implement

That’s not a permanent solution—farmgate prices are still below the full cost of production. But it creates time. Time to explore processor alternatives if better prices are available elsewhere. Time to think about collective approaches. Time to restructure financing if needed. Time to plan transitions thoughtfully rather than under immediate pressure.

And that time matters more than people often realise.

What the Irish Experience Suggests

I’ve been following developments at Dairygold in Ireland because they offer an interesting case study in producer coordination.

When Dairygold announced pricing adjustments this autumn, Irish farming media reported that several hundred farmers quickly organised around concerns about pricing and attended regional meetings with detailed written questions. While the exact figures vary depending on who you talk to, producers on the ground say this collective approach helped prompt partial improvements in the farmgate price rather than further cuts.

Their approach was notably constructive—no protests or supply withholding, just organised attendance at meetings with specific questions about pricing formulas, operational costs, and capital allocation. When a meaningful share of your supplier base shows up with identical written questions, it changes the tone of the conversation.

What’s worth noting is that UK farmers actually have stronger legal frameworks available to them. Recent Defra regulations mandate pricing transparency and good-faith engagement in dairy contracts, and producer organisation structures enable collective dialogue without competition law concerns.

The barrier isn’t legal authority—it’s coordination. And the Irish experience suggests coordination doesn’t require formal structures or membership dues. It requires communication channels, commitment mechanisms, and producers willing to engage constructively with specific questions.

Looking Ahead: What the Projections Suggest

If current pricing dynamics persist, what trajectory should producers anticipate?

Based on AHDB data and Andersons’ outlook analysis, the consolidation pattern we’ve seen for decades looks set to continue—possibly accelerate. According to the Andersons Outlook report covered by Dairy Global, authors Mike Houghton, Oliver Hall, and Tom Cratchley project that GB dairy producers could fall to between 5,000 and 6,000within the next two years. Average herd size would continue climbing, possibly toward 250 head or beyond. Total production would likely remain stable as surviving farms expand.

In 24 months, UK dairy could lose another 1,500 farms—and average herd size will climb past 250 head. 

Exit rates will probably vary significantly by scale and region. Smaller operations—those under 100-150 cows—generally face steeper challenges because their cost structures tend to run higher. Larger operations often achieve better economies of scale on fixed costs. That’s not a judgment about who’s a better farmer; it’s just the economics of spreading overhead across more litres.

Understanding this trajectory helps you make informed decisions about your own operation and timeline.

A Word on Cooperatives

Under UK cooperative law, boards are expected to act in the long-term interests of the society and its members, which often means paying close attention to balance-sheet strength, covenants, and investment needs alongside the current milk price. In practice, management decisions sometimes lean toward protecting the co-op’s viability, even when members face short-term income pressure.

I want to be fair here—boards aren’t being malicious when they make difficult pricing decisions. They’re navigating genuine constraints and competing obligations. But fairness has limits.

Loyalty is a two-way street. If the governance structure consistently prioritizes the institution over the member’s survival, the member has to ask a hard question: Am I actually an owner here, or am I just a supplier with a liability attached?

Because there’s a difference between a cooperative that asks members to share sacrifice during difficult periods and one that protects its margins while members bleed equity. The first is partnership. The second is something else entirely.

Different cooperative models do exist internationally. Some Canadian and European structures have achieved farmgate prices meaningfully above UK equivalents through different charter provisions and member engagement approaches. Whether UK cooperatives could evolve similarly is an open question—but it won’t happen without sustained producer engagement in governance processes. Boards respond to pressure. If members don’t apply it, nothing changes.

The Bottom Line

If you’ve read this far, you’re probably thinking about what all this means for your own situation. Let me offer a few thoughts.

First, understand where your losses are actually coming from. If you’re losing money but your operational metrics—yield, cell count, fertility, labour efficiency—compare reasonably well to industry benchmarks, your challenge is primarily market structure rather than farm management. That distinction matters for how you respond.

Second, don’t wait to act on the things within your control. The herd optimisation, feed work, and revenue diversification I described aren’t heroic measures—they’re sound management practices worth pursuing regardless of market conditions. Many farms should already have been doing this work. Current conditions just make it more urgent.

Third, explore your options on processor relationships. If there are meaningful price differences between your current buyer and alternatives, those differences add up fast. A few pence per litre on a million-plus litres is real money. Understand your contract terms, your notice requirements, and what’s actually available in your area.

Fourth, consider whether collective engagement makes sense for you. The Irish example shows that coordinated, fact-based dialogue can influence how processors make decisions. You don’t need to start a movement—even talking with neighbours about what you’re seeing in your milk cheques and what questions you’d want answered can be valuable.

And finally—and this one matters—make your decisions from clear analysis rather than frustration or self-doubt. If your operation is technically sound and you’re still losing money, that’s important context. It means the problem isn’t fundamentally about you. It means there are structural market factors at work. And understanding that changes how you evaluate your options.

These are difficult times in the UK dairy industry. But difficult times also clarify what matters and what actions are worth taking. The farms that navigate this well won’t be the ones who hoped for markets to improve. They’ll be the ones who understood their situation clearly, acted on what they could control, and made thoughtful decisions about their future.

That’s within everyone’s reach.

Practical Resources

  • AHDB Dairy: Benchmarking tools, market data, and cost of production analysis at ahdb.org.uk/dairy
  • Kingshay: Dairy costings service and buying group information at kingshay.com
  • The Dairy Group: Technical consultancy and feed analysis at thedairygroup.co.uk
  • NAAC Contractor Rates: Current pricing guides at naac.co.uk

Key Takeaways 

  • The gap is £10,000/month. That’s what a 200-cow herd loses when milk sits 8-10ppl below cost. Most UK dairies are there now.
  • It’s not your farming. Processor profits up 22%. Producer numbers down 2.6%. This is market structure—not management failure.
  • Three moves that work. Cull the bottom 15%. Tighten feed with a nutritionist. Capture beef-cross premiums. Combined savings: £7,000-8,000/month.
  • You’re buying time, not salvation. These strategies create breathing room—to switch processors, explore collective action, or plan transitions on your terms.
  • Coordination changes everything. Irish producers shifted pricing through organised, fact-based engagement. UK farmers have stronger legal tools. They just need each other.

Complete references and supporting documentation are available upon request by contacting the editorial team at editor@thebullvine.com.

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Feed Inventory Reality Check: Top Dairies Discover $200,000 They Didn’t Know Was Missing

How Measurement Errors Cost Dairy Farms $200,000 Annually—And What to Do About It

Executive Summary: Here’s the uncomfortable truth: most dairy operations are losing $200,000 annually to feed shrink they can’t see because traditional measurement methods are off by 15-30%. This hidden crisis came to light when Dean DePestel applied mining industry drone technology to his Minnesota dairy’s silage inventory, discovering discrepancies that are now being confirmed across the industry. While the Statz Brothers’ transformation—cutting shrink from 10% to 2-3% and saving $500,000 yearly—demonstrates the potential, you don’t need their million-dollar infrastructure. Five targeted improvements (face management, scale calibration, ingredient tracking, right-sized bunkers, and refusal optimization) can recover $100,000+ annually for an investment of under $20,000. Drone measurement services at $2,000-5,000 per year deliver quarterly measurements accurate to 1-2%, replacing guesswork with data. Any operation can start with a free 30-day test—tracking mixer output, bunks, and pile faces—to identify their gap. With industry consolidation accelerating and processors demanding sustainability documentation, farms that can’t measure and prove their efficiency won’t just lose money—they’ll lose market access.

Dairy Feed Shrink

I recently spoke with a producer in central Wisconsin who discovered something that made both of us pause. After twenty-five years of dairy farming, he finally measured his silage inventory with precision technology and found he had 23% less feed than his calculations suggested. That’s not a rounding error—that’s planning for April and running out in February.

This builds on what we’ve been seeing across the industry. Recent studies show that drone feed measurements reveal errors ranging from 15% to over 30% between traditional estimation methods and actual silage inventory. The financial implications are substantial, yet many operations haven’t recognized this as a solvable problem.

What’s particularly noteworthy is how this revelation emerged from an unexpected source. Dean DePestel, who farms at Daley Farms in Lewiston, Minnesota, happens to be a mechanical engineer. When he read about mining companies using drone technology to measure tailings piles with remarkable accuracy, he wondered if the same approach could work for silage inventory. As documented in a 2022 Ag Proud article, his curiosity led to discoveries that are reshaping how progressive operations think about feed management.

Traditional feed measurement methods are off by 15-30%, while drone technology achieves 1-2% accuracy—the difference between guessing and knowing where $200,000 disappeared

Understanding Where Traditional Methods Fall Short

The dairy industry has relied on tape measures, wheel measurers, and visual estimates for generations. Derek Wawack from Alltech captured it well in a recent Dairy Herd interview when he described these as “about everything to guess what was in forage piles.” These methods served us adequately when margins were wider and feed costs were lower. Current conditions demand better precision.

Harrison Hobart’s work with Alltech’s Aerial Inventory Program reveals why our traditional approaches struggle. Over two years of measuring corn silage density across multiple operations, he documented variations from 12 pounds to 24 pounds of dry matter per cubic foot within drive-over piles. This aligns with what many nutritionists have suspected but couldn’t quantify.

Consider the economics: A typical 1,000-cow operation today faces daily feed costs of $7 to $8 per cow—roughly $2.5 to $2.9 million annually. When research from land-grant universities, including recent work from Hubbard Feeds and Amelicor, shows shrink rates between 5% and 15% on farms without systematic measurement protocols, the financial exposure becomes clear. At 8% shrink—a conservative estimate for many operations—that represents $204,400 annually on a 1,000-cow dairy.

The Compound Nature of Measurement Errors

Pennsylvania State research offers insight into why single-point measurements mislead us. Their work found bunker density averaging 15.5 pounds of dry matter per cubic foot at the bottom, while the top averaged just 11.2 pounds—a 38% variation within the same structure. When we take one or two core samples and extrapolate, we’re essentially guessing.

This variation extends beyond density. I’ve observed haylage piles where dry matter content ranges from 25% to 55% across different sections. These aren’t poorly managed operations—they’re typical farms dealing with the realities of weather windows, equipment limitations, and labor constraints during harvest.

A Wisconsin Case Study in Transformation

The Statz Brothers operation near Marshall, Wisconsin, offers valuable lessons for the industry. This family has been dairy farming since 1966 and currently manages 4,400 cows across two locations. By any conventional measure, they were successful. Yet they faced a challenge many producers will recognize: feed inventory that seemed to disappear faster than expected.

The Statz Brothers dairy slashed feed shrink from 10% to 2.5%, documenting over $500,000 in annual savings—and you don’t need their million-dollar feed center to capture similar gains.

Todd Follendorf, their nutritionist from Cornerstone Dairy Nutrition, quantified what they suspected. As he explained to Dairy Global, “Before, we had shrink percentages of around 10% every single day.” For an operation of their size, that translated into over $1.28 million in annual feed losses.

Their response during a 2015 expansion was instructive. Rather than replicating existing infrastructure, they partnered with Mike Greene, a feed management specialist who had developed the TMR Audit system. Together, they designed a 36,600-square-foot fully enclosed feed center—not simply a commodity shed with walls, but a purpose-built facility that protects feed from placement to feeding.

The documented results speak to what’s possible: shrink rates dropped from 10% to 2%-3%. Even conservative calculations suggest annual savings exceeding $500,000, with the investment paying for itself in under three years.

Yet—and this is crucial for most operations—you don’t need their scale of infrastructure to capture significant benefits.

Practical Improvements That Deliver Returns

Five operational improvements can recover $100,000+ annually for under $20,000 in total investment—no million-dollar feed centers required, just systematic measurement and management.

Through conversations with producers and nutritionists across different regions—from California’s Central Valley to Vermont’s grazing operations—I’ve identified five changes that consistently deliver returns without requiring major capital investment:

1. Optimizing Silage Face Management

Research from UC Davis, widely shared through extension programs, demonstrates that oxygen penetrates up to 3 feet into well-packed silage. When removal rates are too slow—say, 4 inches daily instead of the recommended 6 to 12 inches—that creates an active spoilage zone.

Wisconsin and Penn State extension specialists recommend removing 6 to 12 inches daily in winter, increasing to 10 to 12 inches during warmer months. The technique matters too: scraping from top to bottom rather than digging underneath prevents cracks that increase surface area by 9% or more.

I recently visited a 1,500-cow operation in northeastern Wisconsin that implemented these changes without any equipment purchases. Their estimated savings: $6,000 to $8,000 annually from reduced spoilage alone. A similar operation in California’s San Joaquin Valley reported even higher savings due to the year-round heat stress on exposed faces.

2. Addressing Mixer Scale Accuracy

This issue deserves more attention than it typically receives. Ohio State researchers evaluated mixer wagon scales on 22 dairy farms and found that only half were functioning within acceptable tolerance. A 2% systematic error across all ingredients—easily overlooked in daily operations—costs a 1,000-cow dairy approximately $54,750 annually.

The solution is straightforward: quarterly calibration checks using certified truck scales. The process takes an afternoon, costs $500 to $1,500 for professional calibration if needed, and can identify problems before they compound into significant losses.

3. Ingredient-Specific Shrink Management

Different feedstuffs have dramatically different shrink characteristics, yet many operations apply a uniform percentage across all ingredients. Cornell’s economic analysis and recent coverage in Hoard’s Dairyman highlight this opportunity.

Cottonseed might experience 4% shrink while fine distillers grains can reach 12% to 15%. One documented case at Cornell showed that relocating high-shrink ingredients closer to mixing areas substantially reduced handling losses—a simple change with a meaningful impact.

4. Right-Sizing Face Width to Removal Capacity

Many operations built bunkers for anticipated expansion that hasn’t materialized. An 80-foot-wide bunker makes sense for 2,000 cows, not 1,200. When removal rates are too slow for bunker width, the outer portions essentially compost while you work across.

Penn State’s bunker silo research confirms this is widespread. The solution doesn’t require construction—work bunkers in sections, covering inactive portions. For future construction, consider narrower drive-over piles that match actual removal capacity.

5. Refining Refusal Management

Multiple feeding studies demonstrate that well-managed operations can reduce refusals from 5% to 2% while maintaining or improving intake. On a 1,000-cow dairy, that 3% difference represents $40,000 to $70,000 annually.

This requires discipline: pushing feed every two hours, training someone to read bunks consistently, and finding productive uses for quality refused feed rather than composting it. Yes, labor is challenging, but the returns justify the effort.

The Implementation Journey

When operations begin measuring feed inventory precisely with drone technology or other precision tools, the journey typically follows a predictable pattern. The initial measurement often reveals significantly less inventory than expected—it’s common to discover you’re 15% to 20% short of calculations. This can be unsettling, but it’s also the beginning of improvement.

After the initial surprise, patterns emerge. Operations start connecting measurement data with daily observations. Perhaps loads from one supplier are consistently light, or the mixer has been overfeeding certain pens. By month six, farms implementing systematic changes typically see 2 to 5 percentage points of shrink reduction—not from major investments, but from addressing previously invisible problems.

What I find encouraging is how feed management software integration is evolving to support these efforts. Modern systems can now incorporate drone measurement data directly into inventory tracking, creating real-time dashboards that flag anomalies before they become crises.

The Human Element in Feed Management

Technology alone doesn’t reduce shrink—people using technology systematically do. Successful implementation requires clear ownership and accountability.

The operations achieving the best results designate one person whose primary responsibility (representing 70% to 80% of their time) is feed management. Not someone who feeds when they’re done milking, but someone whose success is measured by feed efficiency and shrink reduction.

Your nutritionist plays a crucial role through weekly or biweekly visits, but they’re designing rations and troubleshooting, not managing daily operations. The distinction matters. Meanwhile, owners or managers need to invest 3 to 5 hours weekly reviewing data and making strategic decisions. This team approach, documented in Michigan State Extension research and Bovine Practitioner guidelines, consistently outperforms fragmented responsibility.

Understanding the Limitations

Professional integrity requires acknowledging the constraints of this technology. Weather presents the primary challenge—most agricultural drones can’t operate in rain or winds exceeding 20 mph. The battery provides 15 to 30 minutes of flight time in good conditions, with less in cold weather.

Since inventory measurement typically occurs quarterly rather than daily, finding suitable flying conditions within a reasonable window is rarely a problem. The 2021 Scientific Reports global drone flyability study confirms this pattern.

Vertical silos present a different challenge—drones can’t see through concrete, so traditional measurement methods remain necessary for these structures. Operations with limited internet connectivity should work with service providers who process data off-farm rather than attempting to manage large file uploads themselves.

Where the Economics Change

Not every operation will benefit equally from precision measurement. A 400-cow grazing operation in Vermont with minimal stored feed faces different economics than a 2,000-cow confinement operation in Wisconsin storing nine months of inventory.

Similarly, Southeast operations practicing rotational grazing might store only 3 to 4 months of silage. For these situations, traditional methods may provide adequate accuracy given the lower total investment in stored feed.

One producer who evaluated but decided against drone measurement made a valid point: “With only 600 cows and buying most of our grain as-needed, the $3,000 service would save us maybe $8,000 annually. That math works, but there are other investments with better returns for our operation right now.” This kind of thoughtful analysis respects that every operation has unique priorities.

Regional Variations and Support Programs

Implementation patterns vary significantly by region. Upper Midwest operations storing 8 to 10 months of feed see the highest returns from precision measurement. California’s large dairies benefit differently—they’re identifying shrink in real time on substantial commodity purchases rather than on stored forage.

What many producers don’t realize is that support exists for adopting these technologies. Multiple states offer cost-share programs through NRCS or state agricultural departments. Wisconsin provides reimbursement for up to 50% of precision agriculture technology costs. Minnesota offers grants for adopting data-driven management systems. These programs, detailed in 2024-2025 announcements from state offices, can significantly improve the economics of adoption.

Looking Ahead: The Strategic Implications

The industry landscape is shifting in ways that make precision feed management increasingly important. Major processors, including Nestlé and Danone, are implementing sustainability documentation requirements. By 2030, operations with 5 years of precision data will have distinct advantages in verifying feed conversion efficiency and optimizing resource use.

These sustainability programs currently offer premiums ranging from $0.50 to $1.50 per hundredweight—significant revenue when applied across annual production. Early adopters are positioning themselves for these opportunities, while others are still evaluating the technology.

The 2030 industry divide is forming right now: Early adopters will have 5+ years of sustainability data, premium payments, and better lending rates, while late adopters scramble to prove efficiency they should have been documenting since 2025.

The labor dynamic adds another dimension. Operations reinvesting feed savings into automation report 30% to 40% reductions in labor requirements while maintaining production levels. With quality labor increasingly difficult to find and costing $20 to $25 per hour, these efficiencies matter.

Financial institutions are also taking notice. Lenders recognize that operations with precision management systems demonstrate better margins and lower default risk, translating to more favorable terms and rates.

USDA projections suggest the U.S. dairy industry will consolidate from approximately 35,000 farms today to between 24,000 and 28,000 by 2030. The operations that thrive won’t necessarily be the largest—they’ll be those that combine appropriate scale with operational efficiency.

A Practical Test for Your Operation

The uncomfortable truth: A simple 30-day tracking test reveals most dairies are missing 8-15% of their calculated feed inventory—that’s $72,000 to $135,000 disappearing annually on a 1,200-cow operation.

For producers interested but not yet convinced, I suggest a simple 30-day evaluation. Track three metrics daily: what your mixer scale indicates you fed, bunk appearance before the next feeding, and visual assessment of pile face movement.

After 30 days, compare purchase records with calculated usage. Most operations discover an 8% to 15% gap that they cannot explain. For a 1,200-cow dairy, that gap represents $72,000 to $135,000 in annual costs at current feed prices.

This evaluation costs nothing but time and reveals whether precision measurement would benefit your operation. If your numbers align within 3% to 5%, this may not be urgent. But if you discover a significant gap—as most do—the investment case becomes clear.

Practical Perspectives for Decision-Making

After examining data from operations across the country and discussing experiences with producers who’ve implemented these changes, several principles emerge:

First, determine whether you have a problem worth solving. The 30-day tracking exercise provides that answer without requiring any investment.

Second, you don’t need to revolutionize your entire feeding system. The five operational improvements outlined earlier can deliver $100,000 or more in annual savings for less than $20,000 in total investment.

Third, for most operations, service arrangements make more sense than equipment ownership. At $2,000 to $5,000 annually for drone measurement services, you access the technology benefits without the complexity.

Fourth, assign clear responsibility. Feed management as a secondary responsibility inevitably underperforms dedicated oversight.

Finally, consider the compound benefits. Early adopters are building advantages in sustainability documentation, labor efficiency, and capital access that extend well beyond immediate feed savings.

The discovery we’re making across the industry is that our traditional “good enough” approach has been far more expensive than we realized. Once operations identify where losses are occurring, they can’t return to the previous level of uncertainty.

For an industry facing continued margin pressure and evolving market demands, the ability to measure and manage precisely may determine who remains competitive. The question isn’t whether perfect measurement exists—it doesn’t. The question is whether three to four accurate measurements annually provide better decision-making than twelve months of estimation.

From my perspective, having watched operations transform their economics through systematic measurement, there’s a substantial opportunity hiding in plain sight on many dairy farms. The challenge—and opportunity—is deciding whether to pursue it.

KEY TAKEAWAYS:

  • You’re losing $200,000 annually—and don’t know it – Traditional feed measurements are off by 15-30%, hiding massive shrink on typical 1,000-cow dairies
  • Test yourself free in 30 days – Track three numbers daily (mixer output, bunk status, pile face movement); most farms discover 8-15% gaps worth $72-135K yearly
  • Five simple fixes deliver $100K+ – Face management ($6-8K), scale calibration ($25-55K), ingredient placement ($30-40K), bunker sizing ($6-8K), refusal optimization ($40-70K)—total investment under $20K
  • Rent accuracy, don’t buy it – Drone services at $2-5K/year provide quarterly measurements within 1-2% (versus 20-40% error with traditional methods)
  • The 2030 divide is forming now – Early adopters secure sustainability premiums ($0.50-1.50/cwt), better lending rates, and processor partnerships, while others scramble to catch up

Complete references and supporting documentation are available upon request by contacting the editorial team at editor@thebullvine.com.

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