As names and faces change through retirements and new hirings, the need for knowledge and training are important for every sector of the dairy industry. This includes education of on-farm employees on the key practices and steps to follow to ensure that the milk leaving the farm is of the highest quality.
Due to limited availability of labor, many producers are making changes to their operations. Large-scale changes include reducing milking to two times per day and/or installing robotic milking systems which can have major impacts on milking procedures and routines. Even smaller-scale changes such as changing pre- and post-dip procedures or making minor adjustments to equipment can have ramifications.
Using automation in the milking system
When making these changes, producers should keep both their long- and short-term goals in mind and avoid sacrificing long-term health and productivity for short-term gains. One way producers may be able to add efficiencies, labor savings and improve cow throughput during milking is by auditing the entire milking routine. Improvements might include minor adjustments to milking equipment settings, employee placement or other modifications to the parlor that improve ergonomics. When making such changes, keep the core components of a strong milking procedure in mind. Ensure every cow still receives the needed amount of stimulation time for good milk letdown, and that pre-milking disinfectants and post-milking disinfectants have the needed contact time to ensure bacteria are killed. These steps are key components of a strong milking routine which helps ensure low somatic cell counts (SCC) and that udder health is maintained.
Automated milking systems are another option gaining in popularity, as they provide a means for cows to voluntarily enter the milking center and essentially milk themselves. These systems can reduce labor-associated costs and free up time for the producer to address other farm and family needs, but still require that the dairy producer pay attention to details around the milking routine for the dairy farm to be successful.
Managed well, this technology may result in increased production, as cows respond to greater access to feed, a greater number of milking opportunities and the consistencies that are a part of the automated process. Cow flow and traffic patterns are key to automated milking system installation success. This technology gives the producer the opportunity to collect data on their animals and their production, such as activity monitoring capabilities to manage reproductive performance or udder health monitoring tools to manage SCC. This data helps the producer manage the herd better without the need for additional labor to monitor the animals effectively.
All automated milking system units require cows that are consistently clean and dry for the pre-milking hygiene to be most effective. The units use a standard protocol for the milking procedure. This consistency has several advantages, as all cows receive the same procedure during milking. However, there are few opportunities to adjust for the conditions of individual cows or a poor environment. Consequently, cow housing and environmental management is critical to success with robotics. Additional facility modifications or new construction may also be necessary prior to installation depending on individual business plans.
Cleaning and sanitation
It is all about the basics. For example, three of the basic steps for cleaning a milk pipeline are as follows:
1. Warm rinse
The water temperature needs to be at 105ºF. The rinse serves two purposes: to get milk residue out of the system and to warm up the stainless-steel pipeline. The rinse should take one pass through the pipeline and then down the drain.
2. Hot detergent
The detergent water temperature needs to start at a minimum of 160°F to ensure the system will drain above 120°F. This cycle needs to circulate seven to 10 minutes with at least 20 good slugs through the pipeline. Chemical concentration will vary depending on the product, but as a general rule you need to be at 1 ounce of detergent to 2 gallons of water to reach a recommended 1,200 to 1,500 parts per million (ppm) alkalinity and 120 to 180 ppm of chlorine when the system drains. Prior to use, it is vital that you test the farm’s water source for hardness, as pH and minerals can impact the performance of the detergent.
The prevention of mineral deposits on equipment surfaces is a major factor in good cleaning. When minerals precipitate onto a surface, they entrap some of the organic milk constituents within the crystalline film. As this process is repeated over a period of time, a milkstone deposit eventually becomes apparent. Milkstone harbors bacteria, and when moisture is present, becomes an excellent medium for bacterial growth which can impact milk quality.
3. Warm acid/acid sanitizer
The acid/acid sanitizer water temperature needs to be at 100°F or lower. This is important, as most acid sanitizers are not engineered to clean at temperatures higher than 105°F. This cycle needs to circulate for five to seven minutes with at least 10 good slugs through the pipeline. Chemical concentration will vary depending on the product, but as a general rule, you need to be at 1 ounce of acid/acid sanitizer for every 5 gallons of water to reach a recommended pH of 3. If using an acid sanitizer, you are good to milk in 12 hours or less.
Most pre-milking sanitizing cycles should start with water temperature around 100°F. This cycle needs to circulate for three to five minutes with at least eight good slugs through the pipeline. The sanitizing cycle needs to be run within 60 minutes of the milking time. Chemical concentration will vary depending on the product, but as a general rule, you need to be at 1 ounce of the chlorine/acid sanitizer to 5 gallons of water to reach a recommended ppm.
Organizing a balanced cleaning and sanitation program using a combination of alkaline detergents to combat organic soils and acid cleaners to control mineral soils is necessary. Posting the cleaning procedures in the milkhouse and proper training on procedures, types of products, the amounts to be used and proper checks helps ensure proper cleaning and sanitation. Following label instructions and consulting with a manufacturer's representative for testing pH and ppm of sanitizer can also help ensure that a balanced system is in place. Even in automated cleaning-in-place systems, the operator will need to confirm the use of proper materials as directed. Observing a complete cleaning cycle is essential because malfunctions may develop within automated systems.
Proper milk cooling and hauling procedures
Today’s economic climate has resulted in an extremely limited labor pool for bulk milk haulers and samplers.
With the current limitations on our milk hauler infrastructure and the additional constraints provided by farm expansions, the need for logistical flexibility and adaptability is greater than ever. Dairy operations are making changes to keep milk moving in these difficult times. This is evident by the different ways farms are handling raw milk prior to shipment. In an effort to expand on transportation efficiencies, more producers are installing vertical silos or converting to direct-load tankers to accommodate growing storage needs.
Modern silo installations on today’s farms can provide superior agitation, cooling and sampling of milk with great accuracy. These storage vessels can accommodate larger volumes while allowing for more efficient loadout capabilities. Many producers use monitoring software that allows haulers to monitor milk levels 24-7 and schedule loadouts more consistently, which helps minimize driver wait times and costly production delays. The options for collecting representative producer samples off of silos are now extremely accurate and can prevent much of the sampling infractions that can occur with bulk tanks.
Direct-load operations use insulated milk transport trailers. Raw milk is pumped directly onto the trailers, immediately after it is harvested, for storage until it leaves the farm. Because these milk trailers do not have agitation or cooling capabilities, the milk loaded onto these units during milking must be rapidly cooled prior to loading.
Most operations use a propylene glycol chiller to instantly cool milk to 35ºF to 38°F to preserve quality and ensure it remains under 40°F until received by the processor. Optimized chiller performance depends on milk flow, starting temperature, coolant temperature, coolant flow, contact area and properties of the heat exchanger.
Although the Pasteurized Milk Ordinance (PMO) requires raw milk to be less than 45°F to be shipped legally from a farm, the actual temperature should remain under 40°F to ensure quality is maintained. Properly cooled milk helps improve hauling efficiencies and prevent milk rejection at the processing facility caused by transportation delays, breakdowns, inclement weather, etc. Farm chillers should be closely monitored before summer weather arrives, to ensure milk is coming out of the chiller cold enough to compensate for the increase in temperatures inside the empty trailers. Most chilling units typically need to be turned down slightly in the spring to avoid issues during transit. Some processing plants have adopted cooler final rinse cycles to combat the inevitable pre-heating of transport vessels during summer months. Friction generated during milk transfer may also raise the temperature a degree or two and needs to be considered as part of the expected milk temperature rise when shipping milk from the farm to the processor.
Dairy producers, haulers and processors that participate in the FDA’s Interstate Milk Shippers program must adhere to the core standards of sanitation required by the PMO for Grade A dairy products to be permitted to cross state lines. In addition to these mandatory federal standards, individual state regulatory agencies may choose to require additional, more stringent standards. Accommodating the evolving equipment needs of today’s dairy farms is a constant challenge. Installing cooling equipment that conforms to regulatory standards and meets individual farm needs is no exception.
All of these practices and approaches mentioned previously are monitored and improved through the work of The Dairy Practices Council (DPC). Visit the website to access these guidelines.
