Milking equipment that is installed properly and functioning at its best is a key part of optimizing milk quality, cow comfort and facility efficiency. In the following paragraphs, I will be offering some tips regarding the installation, operation and maintenance of milking equipment based on my observations over the last 25 years serving dairy producers.

Plan for the future
Whether you are building a new milking center or renovating an existing facility, there is probably no better time spent than the time spent in planning. Visit as many facilities as you can and consult with your equipment dealer, builder, milk inspector and industry fieldperson.

If you think you may be adding milking units or installing milk meters in the future, set slopes and clearances to allow for those additions. Size water lines with an eye toward expansion. If you expand your operation, the benefits of planning for the future will be apparent in time, convenience and labor savings.

Keep your regulatory authority informed
The Pasteurized Milk Ordinance (PMO) requires that plans be submitted to the state regulatory authority before installation occurs. This gives your milk inspector the opportunity to ask questions regarding the design and function of the equipment along with informing you of the requirements of the law.

Invite them to the farm before and during equipment installation; a well-informed inspector will make the process move along easily. Communicate your time line to them and make certain they are able to do a final inspection before you put the equipment into use.

Keep water and electricity as far away from each other as possible
Layout of utilities is a key part of facility longevity. Electrical boxes, raceways and conduit should, as much as possible, be kept above any piping and lines containing water, milk, wash solutions and chemicals.

Moisture near electrical components reduces the life of the components and can be extremely dangerous. I recommend that control panels for both pipelines and bulk tanks, when practical, be installed in an adjacent utility room with only the piping and wiring necessary for the function of the equipment being located in the milkhouse.

Support sanitary and vacuum lines well, at the proper slope, and support them permanently
The 3A standards require that all sanitary lines be supported every 10 feet and within 2 feet of every direction change. ASAE Publication S518 includes guidelines for the proper slope of milking pipelines, based on system operation characteristics.

Milk transfer lines and CIP lines should slope at a minimum of 1 inch in 10 feet toward drains; vacuum lines should slope at a minimum of half an inch in 10 feet toward drains.

Determine what slopes are needed and support the lines permanently with a high-quality bracket that will not rust. Do not use adjustable brackets; the slope of the line should not need to be changed if future needs are taken into consideration.

As much as the practice is discouraged, lines are frequently used as steps and handrails. Adjustable brackets have a tendency to loosen and change the slope, usually in the wrong direction.

Keep hoses as short as practical
Restriction to air flow and milk flow is greatly affected by hose length. Long pulsation hoses affect the length of the transition (A and C) phases of pulsation, which in turn may affect milking speed and teat-end health. Don’t forget the hoses from the pulsators to the fresh-air line; the length of these hoses will affect the C phase of pulsation, leading to shortened D, or “massage” phases.

Not only do loops in milk hoses cause poor drainage, but excessive milk-hose length requires a higher receiver vacuum level to maintain the proper vacuum level at the cow. This can be detrimental to teat-end health, especially when cows are overmilked at the higher vacuum level.

Make equipment easy to inspect
Keep inspection of equipment in mind for Grade A compliance and for troubleshooting quality problems as well. If equipment is inaccessible for inspection, it is a four-point debit on a Grade A survey or FDA check rating.

All milk contact surfaces must be able to be visually inspected. If a weld must be cut to allow for inspection, it is not considered as being accessible for inspection. If equipment must be located in areas that might be considered inconvenient, make certain that a safe method of access is available.

Milking equipment should be easy to service
Equipment should be installed so it can be easily replaced with a minimum of disruption to milking. Pulsators should be mounted using stallcocks rather than mounting them permanently to the vacuum line; the electrical connections for the pulsators can be made via the stallcocks or quick-connect plugs.

This allows a pulsator to be replaced in a matter of seconds. Keep enough spare pulsators on hand to replace small groups of them at a time when they need to be rebuilt. Milk pumps and liquid level controls should be attached with cords and plugs so they may be changed quickly and easily.

It is much easier to work on equipment when it is on a bench rather than in the parlor. Air blow valves are used on many systems to recover milk that cannot be pumped into the tank or truck. The air filter for these valves is a single-service item. If it is not convenient to replace this filter, it usually does not happen as frequently as it should.

Have a means of monitoring equipment function
Many milking systems have the ability to monitor equipment function included in the system software, and there are also monitoring systems that can be added to existing systems. These systems can monitor and create electronic records of such parameters as vacuum levels, pulsator function, chemical concentrations and wash solution temperatures.

Similar devices are also available to monitor temperatures and concentrations for bulk tanks. One of the simplest, time-tested methods of monitoring is the chart-type recording device. A recording thermometer, accompanied by a pH chart recorder, will provide invaluable information when troubleshooting quality issues.

A complete milking system evaluation should be conducted before equipment is put into service and at least annually thereafter. Wash system evaluations should be conducted at least quarterly.

Maintenance is a must
Milking equipment maintenance, whether it is performed by your dealer or your employees, will help to keep your system running smoothly. If you or your employees maintain the equipment, talk with your dealer regarding the preferred maintenance schedule.

There are some general guidelines available for maintenance frequency, but some equipment requires additional maintenance that is outside of these guidelines.

Educate your employees
Well-informed employees are a key to the success of any business. Take the time to show your employees the components of the milking system and explain how the components function together to get the job done. They will be more “in tune” to what is happening and more apt to point out potential equipment problems to you.

There are other items that could be included on this list, but these basics will go far toward making equipment installation and operation go smoothly. Good communication and planning are keys to any project, and this is no exception. PD

Steve Lehman is the technical area supervisor for Michigan Milk Producers Association and is currently serving as the Task Force V Director of the Dairy Practices Council. He resides in Ithaca, Michigan.

PHOTO
Milking equipment maintenance, whether it is performed by your dealer or your employees, will help to keep your system running smoothly. If you or your employees maintain the equipment, talk with your dealer regarding the preferred maintenance schedule. Photo by PD staff.