Measurement of cow comfort during milking on different cluster removal settings through the use of leg-mounted accelerometers

Increasing levels of data are routinely collected on modern dairy farms. These include multiple variables measured by milking machine sensors and software and cow-attached sensor data, used predominantly for fertility and health monitoring. Following milking efficiency principles, including milking gently, quickly, and completely, there is utility in investigating how various milking machine settings affect gentleness of milking through a proxy measurement of cow comfort during milking. The use of leg-mounted accelerometers was investigated as a noninvasive labor-efficient means of estimating cow comfort on different automatic cluster remover (ACR) milk flow-rate switch-point settings. Accelerometer step count measurements during milking were collected from 37 cows divided into 2 groups allocated to either an ACR milk flow-rate switch-point setting of 0.2 kg/min or 0.8 kg/min for a 2-wk period and then crossed over to the other setting. Significantly more rear leg stepping occurred during daily milking (combined step count during a.m. and p.m. milkings) where the ACR activated at 0.2 kg/min (11.7 steps) compared with 0.8 kg/min (10.1 steps). Shorter milking interval between a.m. and p.m. milkings resulted in lower udder fill and reduced milk flow-rate. Under these lower udder fill conditions, rear leg movement, as an indicator of cow comfort, reduced when milk flow-rate switch-point for cluster removal increased from 0.2 kg/min (5.75 steps) to 0.8 kg/min (4.96 steps). There was no significant difference between stepping rates on both cluster removal settings during a.m. milkings. Similarly, no significant differences were noted in assessed postmilking teat condition, which was conducted after a.m. milking. The 0.2 kg/min setting extended total daily milking time by 70 s, resulting in lower mean flow-rates while producing similar milk yield. Higher vacuum levels at the teat-end were also recorded on this milking setting. This provides further incentive to consider cluster removal settings above 0.2 kg/min.

The impact of automated, constant incomplete milking on energy balance, udder health, and subsequent performance in early lactation of dairy cows

Incomplete milking (IM) is one way of mitigating the negative energy balance (NEB) that is characteristic for early lactation and may increase the risk for disease. Our objectives were to test the effects of IM in early lactation on energy balance (EB), metabolic status, udder health, and subsequent performance. To facilitate the practical application, an automated system was used to remove the milking clusters once a predefined amount of milk is withdrawn. Forty-six Holstein cows were equally allocated to either the treatment (TRT, starting on 8 d in milk) or the control group (CON; conventional cluster removal at milk flow rate <0.3 kg/min). Milk removal in the TRT group was limited to the individual cow's milk yield 1 d before IM started and held constant for 14 d. Thereafter, all cows were conventionally milked and records related to EB, performance, and udder health were continued up to 15 wk of lactation. During the 14 d of IM, on average 11.1% less milk was obtained from the TRT cows than from the CON cows. Thereafter, milk yield increased in the TRT group, eliminating the group difference throughout the remaining observation period until wk 15 of lactation. The TRT cows tended to have less dry matter intake and also water intake than the CON cows. The extent of the NEB and the circulating concentrations of fatty acids, β-hydroxybutyrate, insulin-like growth factor-1, and leptin mostly did not differ between the groups. The IM did not affect body condition. Udder health was maintained over the entire observation period in all cows. Our results demonstrate the applicability of the automated cluster removal for limiting milk withdrawal to a defined amount in early lactation. However, it remains to be determined whether the absent effect on energy metabolism was due to the relatively stable energy status of the cows or to the relatively mild IM setting used herein.

Effect of milk flow-rate switch-point settings on milking duration and udder health throughout lactation

The objective of this study was to quantify the effects of different milk flow-rate switch-point settings on milking duration, somatic cell count (SCC), strip milk, teat condition, and milk yield in a grass-based system in a long-term experiment. Much work has already been conducted providing strong support for significant reduction in milking duration without effects on yield through increasing the flow-rate switch-point at which vacuum to the milking cluster ceases and the cluster is removed from the cow by means of a retracting cord. However, in practice many farms have not adopted this labor-saving technology on the basis that it may increase milk SCC. Recent research on commercial Irish dairy herds identified the contagious mastitis-causing pathogen Staphylococcus. aureus as the most prevalent pathogen detected. Staph. aureus could have a cyclical shedding pattern which would inhibit detection at certain time points. Therefore, to reliably assess the effect of milk flow-rate switch-points on SCC, a long-term study was required, consisting of multiple observations on cow-level SCC. The present study filled this gap in knowledge by informing on any effect that ceasing milking at different flow rates may have on milking duration and SCC levels, particularly with regard to spring calving grass-based systems. Four treatments, consisting of milk flow-rate switch-points increasing from 0.2 kg/min to 0.8 kg/min in steps of 0.2 kg/min, were deployed for 31 wk to cows at the Teagasc Research Centre at Moorepark, Ireland. The effect of treatment on daily milking duration was significant. The milking duration for a milk flow-rate switch-point of 0.8 kg/min was 95 s (14%) shorter than for 0.2 kg/min. We did not find a significant effect of increasing the milk flow-rate switch-point from 0.2 to 0.8 kg/min on milk yield or SCC in this long-term study. We did find a significant effect of week of experiment on milk SCC, whereby the SCC of the cows on the experiment increased similarly among treatment groups as lactation progressed. A significant reduction in dead time (time from cluster attachment to reach a milk flow rate of 0.2 kg/min) was also noted as the milk flow-rate switch-point increased. On average, reductions in dead time contributed 12% to the overall reductions in milking duration. Similarly, reductions in low flow time (time from a flow rate of 0.2 kg/min to cluster detachment at the end of milking) contributed 26% to the overall reductions in milking duration. Reductions in dead time and low flow time played a greater role in reducing p.m. milking duration rather than a.m. milking duration due to the milking interval practiced on the research farm.

Factors affecting energy efficiency in herringbone and rotary milking parlours

The United Nations Sustainable Development Goals aim to double the productivity of small-medium food producers (2015-2030), while food demand is estimated to increase by 60 % by 2050. The objectives of this paper were to identify and quantify the relationship between energy efficiency and milking efficiency, identify the main energy consuming processes associated with milking, and investigate whether milking efficiency, energy efficiency or the relationship between them varies depending on parlour type. Energy and milking efficiency data from 26 pasture-based dairy farms in the Republic of Ireland were analysed (17 herringbone, nine rotary). Energy consumption was monitored continuously on the herringbone farms and for two distinct, seven-day periods (observation periods 1 and 2) for the rotary farms. Milking performance was monitored for all 26 farms during these periods. During the observation periods, the rotary farms achieved superior energy efficiency (29.85 Wh kgMilk-1) and milking efficiency (152 cows/hour) than the herringbone farms (32.83 Wh kgMilk-1, 97 cows/hour). Moderate correlations existed between milking efficiency (cows/hour) and energy efficiency (Wh kgMilk-1) for rotary (r = -0.58, R2 = 0.34) and herringbone (r = -0.44, R2 = 0.19). These results indicated that higher levels of milking efficiency were moderately correlated with improved energy efficiency.

Effect of milk flow rate switch-point settings on cow comfort and milking duration

Automatic cluster removers (ACR) operate by ceasing vacuum to the cluster and detaching the milking unit from the udder by means of a retracting cord once the milk flow has decreased to a predefined level (i.e., the milk flow rate switch-point). There is a large body of literature on this topic indicating that increasing the flow rate switch-point (e.g., from 0.2 kg/min to 0.8 kg/min at the udder level) is effective in reducing milking duration while having little effect on milk yield or milk somatic cell count (SCC). However, despite these findings many farms still use a switch-point of 0.2 kg/min because it is believed that emptying the udder completely at each milking is a prerequisite for good dairy cow management, especially in relation to maintaining a low milk SCC. However, there may be additional undocumented benefits in terms of cow comfort to increasing the milk flow rate switch-point, because the low milk flow period at the end of milking is a high-risk time for inducing teat-barrel congestion. The objective of this study was to quantify the effect of 4 milk flow rate switch-point settings on cow comfort, milking duration, and milk yield. In this study, we applied 4 treatments consisting of different milk flow rate switch-points to cows in a crossover design in a spring calving grass based dairy herd in Ireland. The treatments were (1) MFR0.2, where the cluster was removed at a milk flow rate of 0.2 kg/min; (2) MFR0.4, where the cluster was removed at 0.4 kg/min; (3) MFR0.6, where the cluster was removed at 0.6 kg/min, and (4) MFR0.8, where the cluster was removed at 0.8 kg/min. Milking parameters were recorded by the parlor software and leg movements (i.e., kicks or steps) during milking were recorded with an accelerometer. These data were used as a proxy for cow comfort during milking. The results of this study showed significant differences in cow comfort across treatments, as indicated by cow stepping during milking, for a.m. milkings, but these differences were not detected for p.m. milkings, possibly because a.m. milkings were longer than p.m. milkings due to a 16:8 h milking interval on the research farm. Differences tended to distinguish the 2 lower-flow switch-point settings with greater leg movement against the 2 higher-flow switch-point settings with less leg movement during milking. The effect of treatment (milk flow rate switch-point) on daily milking duration was significant. The milk duration for MFR0.8 was 89 s (14%) shorter than MFR0.2. There was no significant effect of treatment on SCC in this study.

Bimodal milk flow and overmilking in dairy cattle: risk factors and consequences

To maximise the return on capital invested in the milking parlour, the largest number of cows should be milked gently and completely in the shortest possible time. Bimodal milk flow and overmilking negatively influence the efficiency of the milk removal process and teat health. This observational study had the objective of investigating the prevalence of bimodal milk flow and overmilking, determining which individual and farm-related variables are associated with these occurrences, and determining the association of overmilking and bimodal milk flow with milk yield and with short- and long-term teat changes. Twenty-one farms were visited once during the study period, wherein the milking routine was timed, the teat condition was assessed, and dynamic evaluation of the milking vacuum was performed. A total of 606 vacuum graphic records were obtained, with an average of 29 ± 3 records per farm, in order to indirectly evaluate the milk flow and thus determine the occurrence of bimodal milking and overmilking time. The average percentage of bimodality per farm was 41.7%. The median overmilking time was 59 seconds, and on average, 78.3% of the cows in a herd were overmilked longer than 30 seconds. An association was found at cow level between the occurrence of bimodal milk flow and days in milk, the total stimulation time, parity, and the preparation lag time. The increase in the mean total stimulation time and the number of passes during preparation were associated with a decrease in the proportion of bimodality in the herd. Parity, reattachment of the milking unit and milking in manual mode were associated with an increase in overmilking time of an individual cow. The presence of a clogged air bleed hole in the claw and the reduction of the cluster removal milk flow threshold were associated with an increase in the herd's median overmilking time. The average milk flow decreased with the increase in overmilking time and with the occurrence of bimodal milk flow. An association was also found between the occurrence of bimodal milk flow and decreased milk yield. A mean of 78.4% of cows per farm had short-term teat changes in at least one teat, and 33.6% of evaluated cows per farm displayed at least one teat with hyperkeratosis. These results emphasise the association of bimodality and overmilking on milking efficiency and reinforce the importance of the milkers' actions and the functioning of the milking parlour for its prevention.

Improving parlor efficiency in block calving pasture-based dairy systems through the application of a fixed milking time determined by daily milk yield and milking frequency

Adjusting end-of-milking criteria, in particular applying a maximum milking time determined by expected milk yield at an individual milking session, is one strategy to optimize parlor efficiency. However, this strategy can be difficult to apply practically on farm due to large differences in session milk yield, driven by milking interval, which affects milking routines and can be limited by in-parlor technology. The objective of this study was to test the hypothesis that a single fixed milking time (duration) could be applied at all milking sessions without compromising milk production or udder health for a range of milking intervals. To test the hypothesis, 4 experimental herds were established: (1) herd milked twice a day (TAD) using a 10- and 14-h interval, (2) herd milked TAD using an 8- and 16-h interval, (3) herd milked 3 times in 2 d using a 10-19-19-h interval, and (4) herd milked once a day (OAD). Herds consisted of 40 cows each, and were established for two 6-wk experimental periods, one in peak lactation and the other in mid-late lactation. Within each herd, half the cows had an end-of-milking criterion of 0.35 kg/min (Flow), and the other half had milking ended after a fixed period of time (FixedT) based on the average milking session yield, the daily milk yield divided by average number of milkings per day, irrespective of milking interval. We found no differences in daily milk yield between end-of-milking criteria due to residual milk from one milking likely increasing the proportion of milk in the udder cistern at the next milking session for the FixedT treatment. However, fat yield was compromised when the percentage of the herd with a truncated milking exceeded an estimated 33% at a milking session, which occurred in the TAD 8-16 herd due to the divergence from the average milking interval (in the case of TAD, 12-12 h). Applying a fixed milking time had no detrimental effects on udder health, except in the OAD herd in mid-late lactation, which had both a higher cell count and new intramammary infection rate. This warrants further investigation, although the majority of cultured bacteria were coagulase-negative staphylococci (CNS). Consequently, we conclude that, in general, with appropriate monitoring (e.g., weekly inspection) to ensure the proportion of the herd with truncated milkings does not exceed 33%, farmers in pasture-based dairy systems can use a fixed milking time to improve parlor efficiency.

Short communication: Increasing the teatcup removal settings of the last milking quarter did not reduce box time in a pasture-based automatic milking system

This research followed our previous experimental and simulation work on the effect of different teatcup removal settings based on the rolling average milk flowrate and on milking duration at the quarter and udder levels. The aims of this experiment were to (1) quantify the differences in quarter milking duration in a pasture-based automatic milking system and (2) test the effect of increasing the milk flowrate at which teatcups are removed on the last milking quarter on udder milking duration, box time, milk production rate, and somatic cell count (SCC). Milking duration is an important component of efficiency and profitability in conventional and automatic milking systems. Additionally, quarters within an udder have significantly different milk yields and milking durations. This study used data from April to May 2018 of a pasture-based automatic milking system to evaluate quarter milking duration differences between quarters of an udder. Subsequently, we experimentally evaluated the use of 2 percentage-based teatcup removal settings applied to the last milking quarter (i.e., the last quarter with a teatcup still attached) on milking duration, box time, milk production rate, and SCC. The teatcup removal settings were at 30 or 50% of the last quarter's rolling average milk flowrate, while the other quarters remained at the 30% level. The selection of the quarter that would receive the more aggressive teatcup removal setting was determined by identifying the last quarter with a teatcup attached in every milking. Sixty-nine cows were divided into 2 groups that each received 1 of the 2 treatments for a 1-wk period and then switched to the other treatment for a second week. For the months of April and May 2018, quarter milking duration was significantly different between the quarter with the longest and the second longest milking duration within an udder. The quarter with the longest milking duration was milked on average 49 s longer than the quarter with second longest milking duration. However, in 36% of the milkings, the quarter with the longest milking duration was different from that of the previous milking. In the experimental part of this study, we saw no differences in milking duration, box time, milk production rate, or SCC between the 30 and 50% teatcup removal setting applied to the last milking quarter. Further research on using a variation of this percentage-based setting to target the quarter with the average longest milking duration or using an absolute milk flowrate switch-point or a maximum milking duration setting on the last quarter for reducing cow milking duration and box time is warranted.

A randomized trial to study the effect of automatic cluster remover settings on milking performance, teat condition, and udder health

The objectives were to study the effect of 2 different automatic cluster remover settings on (1) milking characteristics, (2) milk component yields, (3) teat tissue condition, and (4) udder health. In a randomized controlled field trial, Holstein cows (n = 689) from 1 commercial dairy farm with a thrice-daily milking schedule were allocated to 2 treatment groups. Treatment consisted of a cluster remover take-off milk flow threshold of 1.2 (ACR1.2) or 0.8 kg/min (ACR0.8) for 57 d. Milking characteristics (milk yield; and milking unit-on time, MUOT) were obtained with electronic on-farm milk meters. Composite milk samples were collected and analyzed for fat, protein, lactose, and somatic cell count. Machine-milking-induced short- and long-term changes to the teat tissue condition were assessed visually. General linear mixed models demonstrated differences in MUOT, whereas no meaningful differences in milk yield were detected. Milk yield (least squares means, 95% confidence interval) was 11.3 (10.9-11.8) and 11.3 (10.8-11.8) kg in groups ACR1.2 and ACR0.8, respectively. The effect of treatment on MUOT was modified by parity. Milking unit-on time in first-, second-, and ≥third-lactation cows, respectively, was 260.7 (252.0-269.4), 257.8 (247.4-268.1), and 260.2 (252.6-267.9) s in group ACR1.2; and 273.7 (264.9-282.5), 279.1 (269.4-288.8), and 295.7 (287.9-303.6) s in group ACR0.8. We detected no meaningful differences in milk component yields or linear somatic cell score. Least squares means in groups ACR1.2 and ACR0.8, respectively, were milk fat yield, 0.42 (0.40-0.44) and 0.42 (0.40-0.44) kg; milk protein yield, 0.36 (0.35-0.37) and 0.37 (0.36-0.37) kg; milk lactose yield, 0.61 (0.60-0.63) and 0.63 (0.61-0.64) kg, and linear somatic cell score, 1.9 (1.8-2.0) and 1.9 (1.8-2.0). A generalized linear mixed model revealed an effect of treatment on machine-milking-induced short-term changes. The odds of short-term changes to the teat tissue were lower for cows in group ACR1.2 [odds ratio (95% confidence interval) = 0.78 (0.63-0.96)]. No meaningful differences were detected in machine-milking-induced long-term changes between treatment groups. Increasing cluster remover take-off milk flow threshold from 0.8 to 1.2 kg/min decreased individual milking duration and alleviated machine-milking-induced short-term changes to the teat tissue without adversely affecting milking performance or somatic cell count. Future studies are warranted to investigate the effect on milk production and udder health over a whole lactation period.

Review: Milking machine settings, teat condition and milking efficiency in dairy cows

Because of technical limitations, an impact of machine milking on the teat tissue cannot be avoided. The continuance of this impact during and after milking depends on a variety of factors related to the physiological regulation of milk ejection, as well as the different production systems and milking machine settings. Milking machine settings aim to achieve a high milking performance, that is, short machine-on time at a maximum of milk harvest. However, a high milking performance level is often related to an impact on the teat tissue caused by vacuum or liner compression that can lead to pathological dimensions of congestion of the tissue or hyperkeratosis as a long-term effect. Toward the end of milking a decrease of milk flow rate causes a raise of mouthpiece and teat end vacuum levels and hence an increase of the impact on the teat tissue and the risk of tissue damage. The mechanical stress by the milking machine activates a cascade of cellular mechanisms that lead to an excessive keratin growth and thickening of the keratin layer. Consequently, a complete closure of the teat canal is disabled and the risk of bacterial invasion and intramammary infection increases. Another consequence of high vacuum impact is fluid accumulation and congestion in the tissue of teat tip and teat basis because of an obstruction in venous return. The present review paper provides an overview of the available scientific information to describe the interaction between different levels and types of system vacuum, mouthpiece chamber vacuum, teat end (claw) vacuum, liner pressure, and the risk of short-term and long-term impacts on the teat tissue.

Short communication: Effects of changing teatcup removal and vacuum settings on milking efficiency of an automatic milking system

The aim of this experiment was to assess strategies to reduce milking time in a pasture-based automatic milking system (AMS). Milking time is an important factor in automatic milking because any reductions in box time can facilitate more milkings per day and hence higher production levels per AMS. This study evaluated 2 end-of-milking criteria treatments (teatcup removal at 30% and 50% of average milk flowrate at the quarter-level), 2 milking system vacuum treatments (static and dynamic, where the milking system vacuum could change during the peak milk flowrate period), and the interaction of these treatment effects on milking time in a Lely Astronaut A4 AMS (Maassluis, the Netherlands). The experiment was carried out at the research facility at Teagasc Moorepark, Cork, Ireland, and used 77 spring-calved cows, which were managed on a grass-based system. Cows were 179 DIM, with an average parity of 3. No significant differences in milk flowrate, milk yield, box time, milking time, or milking interval were found between treatments in this study on cows milked in an AMS on a pasture-based system. Average and peak milk flowrates of 2.15 kg/min and 3.48 kg/min, respectively, were observed during the experiment. Small increases in maximum milk flowrate were detected (+0.09 kg/min) due to the effect of increasing the system vacuum during the peak milk flow period. These small increases in maximum milk flowrate were not sufficient to deliver a significant reduction in milking time or box time. Furthermore, increasing the removal setting from 30% of the average milk flowrate to 50% of the average milk flowrate was not an effective means of reducing box time, because the resultant increase in removal flowrate of 0.12 kg/min was not enough to deliver practical or statistically significant decreases in milking time or box time. Hence, to make significant reductions in milking time, where cows have an average milk flow of 2 kg/min and yield per milking of 10 kg, end-of-milking criteria above 50% of average milk flowrate at the quarter level would be required.

The effects of incomplete milking and increased milking frequency on milk production rate and milk composition1

Increased milking frequency and incomplete milking have differential effects on milk yield and mammary gland physiology that are important for optimization of milking practices in dairy herds. The objectives of this experiment were to determine the effects of increased milking frequency and incomplete milking on milk production rate (MPR) and milk composition and to determine if milking 3 times daily (3×) could rescue the negative production effects of incomplete milking. Twenty-two multiparous cows were enrolled onto this experiment beginning at 5 days in milk (DIM) and continuing through 47 DIM. A split-plot design was used to randomize the 2 treatments, which were milking frequency and incomplete milking. Eleven cows were randomly assigned to be milked 2 times (2×) daily and 11 cows were randomly assigned to be milked 3×. Within each cow, a contralateral half-udder was randomly assigned to be incompletely milked (30% milk remaining in the gland; IM), and the other half-udder was randomly assigned to be milked completely (CM). Quarter-level milk yields were recorded at each milking session. Milk samples from all quarters were collected twice weekly at the beginning of the morning milking for analysis. Cows milked 2× tended to have reduced MPR compared with 3× milked cows (1.81 ± 0.06 vs. 1.97 ± 0.06 kg milk/h; P = 0.06). Half-udders that were CM and IM produced 1.09 ± 0.03 and 0.80 ± 0.03 kg milk/h, respectively. There was an interaction between incomplete milking treatment and week of lactation (P = 0.04). No interaction was detected between milking frequency and incomplete milking for MPR or milk components. Cows milked 3× had increased milk fat percent (1.93 ± 0.09% vs. 1.65 ± 0.09%, P = 0.047), decreased milk lactose percent (4.80 ± 0.04% vs. 4.93 ± 0.04%, P = 0.04), and exhibited no differences in milk protein percent or milk somatic cell count (SCC) compared with cows milked 2×. Half-udders that were IM had increased milk fat percent (2.15 ± 0.07% vs. 1.43 ± 0.07%, P < 0.0001), decreased lactose percent (4.75 ± 0.03% vs. 4.99 ± 0.03%, P < 0.0001), increased milk log10SCC (4.22 ± 0.05 vs. 4.41 ± 0.05, P = 0.0004), and no differences in milk protein percent compared with CM half-udders. These results indicate that a 3× milking frequency in IM half-udders was not able to improve milk production compared with IM half-udders milked 2×. Our results indicate that 30% milk remaining in the gland had an irreversible impact on milk yield as increased milking frequency was not able to reverse the milk yield lost.

Increased take-off level in automatic milking systems – effects on milk flow, milk yield and milking efficiency at the quarter level

This research communication describes how different detachment levels (0.48, 0.3 and 0.06 kg milk/min) at the quarter-level affect milk flow profiles and overall milking efficiency in automatic milking systems. We hypothesized a higher detachment level would result in greater mean flow rates without affecting the volume of harvested milk per cow during 24 h compared to lower detachment levels. The data suggest milk flow decreased to a rate below the overmilking limit within the 6-s delay time required for termination in all treatments, but the duration of overmilking was shorter for the greatest detachment level compared to the other treatments. We conclude that setting a detachment level at a greater milk flow rate reduces the duration of overmilking without affecting the amount of milk harvested when applied to cows in mid-lactation during quarter-level milking. We also suggest that the steepness of the decline phase of the milk flow curve might have a larger effect than the actual detachment level on the duration of overmilking.

Evaluating rates of technology adoption and milking practices on New Zealand dairy farms

This study assessed technology use and evaluated rates of technology adoption and milking practices on New Zealand dairy farms. Industry surveys were conducted in 2008 and 2013, when farmers were asked a series of questions relating to their physical farm details, their role in the business, their attitudes towards technology, the technologies they had on-farm and their levels of satisfaction. In total, 532 and 500 respondents were questioned in the two surveys, respectively, with a similar representation of rotary and herringbone dairies. Questions relating to attitudes towards new technologies were subjected to a cluster analysis using the 2013 dataset. Farmers were classified into two categories, ‘fast’ and ‘slow’ adopters. Fast adopters are more likely to have a rotary, with a larger farm and more cows. The most common technology in herringbone dairies is automatic vat washing and in rotary dairies automatic cluster removers (ACR). Rotary dairies equipped with ACR, automatic drafting and automatic teat spraying achieve greater labour utilisation (cows/labour unit). Around half of farmers with herringbone dairies sometimes or always wait for slow-milking cows to milk out and 85% of farmers do not know the their ACR settings, highlighting significant potential to improve milking efficiency. Overall, technology is associated with greater labour utilisation. However, the benefits of each technology should be scrutinised to ensure appropriate investment decisions are made by farmers.

Principles for maximising operator efficiency and return on investment in rotary dairies

This study quantified the effect of rotary size, platform speed, cluster attachment time, milk yield and end-of-milking criteria on cow throughput, operator efficiency and return on investment. A model was developed to predict the mean and standard deviation of cow milking duration for a given milk yield using milking data collected from commercial dairy farms in New Zealand. After accounting for the effect of end-of-milking criteria, this estimate was used to calculate the expected cow throughput and operator efficiency for a given platform speed, rotary size and cluster attachment time. The economic return of investing in rotaries of 44–80 bails, relative to a 40-bail rotary, was evaluated using a 25-year internal rate of return. The economic return of installing automatic cluster removers (ACR) was also examined. Estimated cow throughput increased with increasing platform speed and ACR threshold for a 50-bail rotary (a common rotary size) and the largest single gain in cow throughput came from changing the ACR threshold from 0.2 to 0.4 kg/min. Further increases had less impact, especially at lower platform speeds. However, for larger rotaries, maximum operator efficiency could be achieved using a variety of platform speeds and end-of-milking criteria. A larger rotary was required to achieve maximum potential operator efficiency, for a given cluster attachment time, as milk yield was increased. Increasing the minimum cluster attachment time decreased maximum potential operator efficiency. Consequently, operator ability and anticipated milk yield are key parameters when selecting the number of bails in a new-build rotary. Seventy- and 80-bail rotaries were generally not more operator efficient than 60-bail rotaries. Economically, the 50-bail rotary allowed the greatest labour saving per dollar invested for a typical farm conversion in Canterbury, New Zealand, although the ultimate choice of rotary size depends on the individual farm situation. The internal rate of return for installing ACR decreased with increasing rotary size, but was always positive. Farmers should carefully evaluate their options before investing in a new rotary.

Milking efficiency of swingover herringbone parlours in pasture-based dairy systems

The objective of this study was to collect and analyse milking data from a sample of commercial farms with swingover herringbone parlours to evaluate milking efficiency over a range of parlour sizes (12–32 milking units). Data were collected from 19 farms around the Republic of Ireland equipped with electronic milk metres and herd management software that recorded data at individual milking sessions. The herd management software on each farm was programmed to record similar data for each milking plant type. Variables recorded included cow identification, milking date, identification time, cluster-attachment time, cluster/unit number, milk yield, milking duration, and average milk flow rate. Calculations were performed to identify efficiency benchmarks such as cow throughput (cows milked per h), milk harvesting efficiency (kg of milk harvested per h) and operator efficiency (cows milked per operator per h). Additionally, the work routine was investigated and used to explain differences in the benchmark values. Data were analysed using a linear mixed model that included the fixed effects of season-session (e.g. spring-AM), parlour size and their interaction, and the random effect of farm. Additionally, a mathematical model was developed to illustrate the potential efficiency gains that could be achieved by implementing a maximum milking time (i.e. removing the clusters at a pre-set time regardless of whether the cow had finished milking or not). Cow throughput and milk harvesting efficiency increased with increasing parlour size (12 to 32 units), with throughput ranging from 42 to 129 cows/h and milk harvesting efficiency from 497 to 1430 kg/h (1–2 operators). Greater throughput in larger parlours was associated with a decrease in operator idle time. Operator efficiency was variable across farms and probably dependent on milking routines in use. Both of these require consideration when sizing parlours so high levels of operator efficiency as well as cow throughput can be achieved simultaneously. The mathematical model indicated that application of a maximum milking time within the milking process could improve cow throughput (66% increase in an 18-unit parlour when truncating the milking time of 20% of cows). This could allow current herd milking durations to be maintained as herd size increases.