Facility Recommendations in Tropical Climates

Facility Recommendations in Tropical Climates Modernizing Dairy Farms in Costa Rica David W. Kammel Biological Systems Engineering UW Madison

Land Base and Dairy Industry Wisconsin Land Base 169,637 square km Dairy Herds 10,860 2014 Dairy Cows 1,271,000 Average herd size 117 cows Milk production 9860 kg/year/cow

Number of Farms Wisconsin Dairy Farms by Herd Size, 2007* 8,000 6,000 6100 2007 14,400 herds 2014 10,860 herds 4,000 3600 2,000 1900 1800 750 250 0 1-29 Head 30-49 Head 50-99 Head 100-199 Head 200-499 Head 500 + Head *Preliminary estimate. Source: USDA/NASS, Farms, Land in Farms, and Livestock Operations Summary.

Temperatures in San Jose, Costa Rica and Madison, WI USA Weatherbase.com Intellicast.com

Facilities are tools to implement a management plan Water Grazing Paddocks Corrals Feed Storage Machinery Storage House Water Feed Storage Manure Storage Water House Milking Center Components of a Dairy Farm System DVM Gordy Jones

Facility Design Goals: Allow the implementation of the management plan to express the cow s genetic potential Provide: Be: Cow Comfort Clean dry environment for cows Adequate fresh air, feed, and water Labor efficient Safe for both workers and cows Environmentally friendly Produce: Quality Food Profitable Dairy Business Consider flow of cows, feed, manure, and people

Dairy modernization is investing in facilities that: Improve cow comfort Increase dry matter intake (DMI) Improve labor efficiency Improve operator health and safety Increase profit Improve quality of life

Cow Comfort Housing system design which: Protects the cow from severe environmental conditions Provides adequate space for resting, eating, drinking, and walking Limits the likelihood of injury and/or disease Considers all the cows in the herd (especially the subordinate cows)

Daily Activity (Hours per Day) Dairy Cow Daily Time Budget Grazing versus Free Stall Confinement System 24 22 20 18 16 14 12 10 8 6 4 2 0 3.9 3.6 8.3 2.7 9 Grazing 11.8 3.1 5.5 Free Stall Other Lying Milking Feeding

Dairy Animal Management Plan Needs of the cow The cow is number one priority Provide an environment that can express the genetic potential of the cow Provide adequate space for all management groups Provide optimal cow comfort Provide fresh air by ventilation Adequate space for resting, eating and drinking Clean & dry resting space Adequate space to move to feed and water Minimize social and environmental stress Safe from injury Manage weather extremes Cow cooling in warm season Shelter in the wet season

Dairy Animal Management Plan Needs of the owner and workers Effectively utilize a farm s resources Land Capital Labor Genetic potential of herd Safe & labor efficient Milking Feeding Manure Handling Cow movement Environmentally sustainable

Farmstead Planning in Steps Identify Limitations & prioritize investments Determine a budget based on: Number of cows Financial situation Risk tolerance Develop farmstead master plan Identify planning zones for milking, housing, feeding, feed storage, and manure storage Consider future growth (beyond the first step) Phased construction (investment) Consider current needs and long term goals Reuse existing facilities if possible Build new facilities as needed

Farmstead Master Plan A master plan is a set of drawings and documents that describers the site plan with: Physical boundaries Natural boundaries Existing facilities Planned/ proposed improvements Defines the benefits/limits of the site

Existing Farmstead North

Master Farmstead Plan Planning Zones North Lane Water Feed Storage Water Machinery Storage House Milking Center Housing Corrals Housing Water Lane Lane House Manure Storage

Master Farmstead Plan Phased Construction Projects North Water Feed Storage Lane Phase 4 House Phase 5 Housing Phase 1 Housing Water Machinery Storage Phase 5 Milking Center Corrals Manure Storage Water Lane House Phase 3 Phase 2

Limitations Possible Facility Improvements Wet weather o o o Feed storage area Shelter feeding area Shelter resting area Hot Weather o o o o o Shade milking area Shade feeding area Shade resting area Sprinklers Velocity fans

Facility Investments Improved feeding area Shade/shelter the feeding area (with capacity to expand) Shade/shelter the resting area (with capacity to expand) Shade /shelter holding area and parlor Heat Stress Mitigation Sprinklers Velocity Fans Feed storage Manure storage

5.00m Feed Lane 9.30 m 4.30m Alley Water Feeding Platform 30.00m 4.00 m 4.00 m 14.00 m 4.00 m 4.00 m Resting Space Water Fence Water Alley Feed Platform 50 cows @ 0.60 m/cow Feed Lane

Feeding Platform

Hourly grazing of cows (Botheras, 2007)

Percentage of cows using shade Tucker, C.A., A.R. Rogers, K.E. Schutz

Shade Design Shade Area Cows 4.0-5.0 s.m. 200 kg calf 2.0 s.m. 400 kg heifer 3.0 s.m. Minimum of 50% sun blockage 4.3 m height minimum North South Allows drying under shade East West Less Sun penetration Natural Shade Controlled access to allow drying Permanent Shade Controlled access to allow drying Improved area (concrete) Portable/movable shade Allows drying Separate water locations, salt/mineral feeders, feed locations

North South versus East West Shade Buffington Collier 1983

Portable Shade

Permanent Shade

5.00m Feed Lane 9.30 m Shade 4.30m Alley Water Shade over feeding platform 30.00m 4.00 m 4.00 m 14.00 m 4.00 m 4.00 m Resting Space Water Fence Water Alley Shade Feed Platform 50 cows @ 0.60 m/cow Feed Lane

Shade over feeding platform

Water 4.30m 5.00m Alley 13.60 m Shade Feed Lane 4.30m Alley Water Shaded Feeding Platform Drive Through Feeding 30.00m 4.00 m 4.00 m 14.00 m 4.00 m 4.00 m Resting Space Water Fence Water Alley Shade Feed Platform 50 cows @ 0.60 m/cow Feed Lane Feed Platform 50 cows @ 0.60 m/cow Alley Water Fence Water

Shade Over Feeding Platform

Shade Shelter Over Feeding Platform Shade Over Feeding Platform

Cow Kennel

Cow Kennel McFarland 2014

3.10 m 6.20 m 3.10 m Water Water Single row FS with feed platform 31.2 m Curtain Sidewall 25 FS @ 1.2 m Alley

Single Row Free Stall Barn

Cow Kennel McFarland 2014

4.00 m 3.10 m Water 12.30 m Water 9.30 m 3.10 m 3.10 m Cow Kennels with drive by feeding 34.80 m 4.80 m 25.20 m 4.80 m Curtain Sidewall 29 FS @ 1.2 m Alley 21 FS @ 1.2 m Alley Feed Platform Curtain Sidewall

Cow kennels with drive by feeding http://www.farmplus.co.uk/galleries/gal_cowkennels.html

6.0 m 11.0 m 5.0 m Water Water Outside Alley Outside Alley 3.0 m Water 5.0 Water 11.0 m 3.0 m Housing and Feeding Shelters 40.0 m 5.0 m 30.0 m 5.0 m Alley 25 FS @ 1.2 m o.c. 25 FS @ 1.2 m o.c. Alley Outside Buffer Alley Feed Traffic Lane 40.0 m

Feeding Shelter

Housing Shelter

Bedded Pen Shelter

Housing and Feeding Shelters

Feeding Shelter

Housing Shelter

3.1 m Water Water 9.3 m 3.1 m 3.1 m 2 row Freestall Shelter 30.0 m Curtain Sidewall 25 FS @ 1.2 m Overhead Door Alley 25 FS @ 1.2 m Curtain Sidewall

2 row Freestall Shelter Two Row Free Stall Barn

Wooden Freestall Divider

Plastic Freestall Divider

Steel Freestall Divider With Deep Bed of Sand

Deep Bed of Organic Solids

Freestall Mattress

3.10 m 3.10 m 2.80 m Water Water 2.80 m 12.0 m 3.00 m 5.00 m 3.10 m 1.10 m 2 row Freestall Barn with Inside Feeding 49.20 m 19.20 m 30.00 m 16 FS @ 1.2. m o.c. Drive By Feeding Feed Platform Alley 33 FS @ 1.2 m o.c. Alley 4.80 m 39.60 m 4.80 m

2 row Freestall Barn with Inside Feeding

3.1 m Optional Headlocks Feed Platform 9.3 m 3.1 m 3.1 m Outside Alley 30.0 m Two Row Freestall Barn Outside Feeding Manure Gate 30.0 m Curtain Sidewall 2.4 m 3.7 m Water 1.2 m 25 FS @ 1.2 m Overhead Door Alley 6" Open Ridge recommended 25 FS @ 1.2 m Water Curtain Sidewall Hoop Freestall Barn 2 Rows With Outside Feeding Gate

Two Row Freestall Barn Outside Feeding

Two Row Freestall Barn

Outside Feeding

3.10 m Water Water 4.00 m 19.20 m 5.00 m 4.00 m 3.10 m Water Water 2 row Freestall barn with drive through feeding 31.20 m Curtain Sidewall 25 FS @ 1.2 m Alley Feed Alley Alley 25 FS @ 1.2 m Curtain Sidewall

2 row Freestall barn with drive through feeding

20.30 m 16.00 m 8.0 m 8.0 m 4.30 m 5.0 m Bedded Pen Shelter with drive by feeding Shelter Bedded Resting Space Feed Lane Alley Water 30.00m 4.00 m 4.00 m 14.00 m 4.00 m 4.00 m Bedded Resting Space 50 Cows @ 10 s.m. = 500 s.m. Water Fence Water Alley Feed Platform 50 cows @ 0.60 m/cow Feed Lane

Bedded Pen Shelter with drive by feeding

3 row Freestall barn with drive by feeding Water Water 4.30 m 5.00 m 3.10 m 3.10 m 6.00 m 21.50 m Freestalls Feed Alley 26.40 m 4.80 m 16.80 m 4.80 m 22 FS @ 1.20 m o.c. Alley 14 FS @ 1.20 m o.c. 14 FS @ 1.20 m o.c. Feed Lane Alley Lane Alley

3 row Freestall barn with drive by feeding

Water Alley Fence 8.00 m Bedded Resting Space 50 Cows @ 10 s.m. = 500 s.m. Water Bedded Resting Space 16.00 m 20.30 m Shelter Water 4.30 m 5.0 m 4.30 m Alley Water Shelter 20.30 m 16.00 m 8.00 m 8.00 m 8.00 m Bedded Resting Space Bedded pen with drive through 30.00m feeding 4.00 m 4.00 m 14.00 m 4.00 m 4.00 m Bedded Resting Space 50 Cows @ 10 s.m. = 500 s.m. Water Fence Water Alley Feed Platform 50 cows @ 0.60 m/cow Alley Feed Lane Feed Lane 4.00 m 4.00 m 14.00 m 4.00 m 4.00 m 30.00m

Bedded pen with drive through feeding

Calf Housing Hutches

Calf Housing Calf Barn w/ Individual Pens

Calf Calf Housing Transition Group Housing Calf Pens Super Hutch

Calf Housing Weaned Calf Super Hutch

Calf Calf Housing Transition Weaned Housing Calf Super Hutch Super Hutch

Calf Housing Weaned Calf Barn w/ group Pens

Heifer Housing Bedded Group Pens with outside feeding

Heifer Housing Bedded Group Pens with sheltered feeding

Heifer Housing Bedded Platforms

Heifer Housing Bedded Group Pens with sheltered feeding

Shaded Holding Area

Low Cost Parlor Plan Wall Cow Entry Back Gate Optional Personal Pass 3-5% Slope Optional Receiver Location Holding Area 1.4 square meter per cow Hinged Gate Sump Below Steps or Ladder 2% Slope Floor Drain 1.2 m Wall Entrance Optional Crown 25 mm 2% Slope 2.4 m Gutter Drain to Sump Cow Platform 2% Slope Rump and Kick Rail Floor Drains 1.8 m- 2.4 m Spacing 70 Milking Unit Spacing 600 mm Jersey 675 Holstein Jersey 1200 mm Holstein 1350 mm Adjustable +/- 100 mm Parking Angle Breast Rail Varies Jersey 600 mm x # Stalls Holstein 675 mm x # Stalls Adjustable Breast Rail Wall Support Operator Area Steps Adjustable Breast Rail Post Support 100 mm Offset Edge of platform to rump Rail Return Optional Drain Gate Swing Varies Optional Chop Gate 1.2 m Entrance Optional Side Exit Exit Area Cross Over Front Cow Exit 1.8 m Cross Over Varies See Cross Section

900 mm 600 mm 900 mm Frame Construction 50 mm x50 mm Square Tube or 50 mm Diameter Tube Typical 1100 mm Vacuum Line Frames Spaced @ 1.8 m-2.4 m on center Typical 75 mm Drop Optional Neck Rail Head Space 600 mm Minimum450 mm Breast Rail Optional Adjustable Breast Rail Support 200 mm Optional Manure Splash Guard Varies 200 mm 750 mm Rump Rail Milk Line Slopes Kick Rail 800 mm +/- 50mm 1500 mm Minimum 600 mm +/- 50 mm 600 mm +/- 50 mm 1800 mmtypical 125 mm 75 mm Maximum Height Curb or Nib Option A Frame Option Dimensions may vary 70 Degree Angle Jersey-Holstein 1200 mm-1350 mm Adjustable +/- 100 mm 100 mm Offset ** Cow Platform Width Typical Ceiling Height Optional Adjustable Breast Rail 2050 mm Minimum HolsteinSupport 1900 mm Minimum Jersey 2.1 m-2.4 m Low Cost Parlor Plan 200 mm-300 mm Overhang 1000 mm +/- 50 mm Typical 25 mm Crown Optional 200 mm Optional Gutter to Sump 150 mm Optional Gutter and or Drains ** Cow Platform Width Recommeded Holstein 2400 mm Jersey 2100 mm Interior Wall to Wall Holstein 5.7 m minimum, 6.7 m Typical Interior Wall to Wall Jersey 5.4 m minimum, 6.1 m Typical

Low Cost Parlor

Manure Collection and Transfer

Feeding Platform Manure Collection

Alley Manure Manure Storage Collection (1 of 2)

Alley Manure Collection

Facilities are tools to implement a management plan Grazing Paddocks Lane Housing North Housing Water Feed Storage Water Machinery Storage House Milking Center Corrals Corrals Manure Storage Lane Water Lane House

Preguntas!