Rotary milking parlors are continually advancing, opening the door to a diverse range of auxiliary technologies that seamlessly integrate with precision milk harvesting and cow behavior monitoring systems. These advancements lead to growing interest in automated sorting systems for both new and existing rotary milking parlor facilities. Designing a successful sort system can be extremely beneficial to dairy operations, especially when cow flow and space expectations are considered from the start.
Why sort systems?
Farms experience immediate benefits from implementing sort system technology, including increased efficiency and improved ergonomics by reducing physical effort spent sorting cows. These systems also allow for dairy farms to manage cows by exception, sorting only those that need handling while the rest are uninterrupted. If set up correctly, sort systems can also provide ample space to conduct safer cow management in a more controlled environment than a drylot or freestall barn.
Step 1: Designing the system
If corners are cut in the design process, the sort system runs the risk of failing before it is even operational. Take time to carefully consider all aspects of the cow’s sorting experience and what employees need to use the equipment. Rotary size and speed can play a significant role in placement of sort gates, and each design needs to accommodate cow flow for the maximum number of cows the rotary will milk per hour. Installing sort gates far enough away from the rotary exit creates adequate space for cows to queue up and pass through the sort system in a single-file line.
Due to their physiology and vision limitations, cows prefer to enter sort gates at a slight angle and in well-lit areas. Minimize tight turns and provide a direct path from the rotary exit to the sort gate. For better traction, groove concrete or implement rubber mats along the way.
If multiple sort gates are required, aim for symmetry in gate positioning and layout of sorting areas. Cows naturally prefer the path of least resistance and develop a preference for one path over another, which is why symmetry is important to ensure a consistent experience for the cow regardless of the gate she chooses. Keeping the design as simple as possible is the best option, as overcomplicated layouts may cause bottlenecks, overwhelm employees and take longer for cows to adapt.
Worker access gaps in fencing are an absolute must, ensuring employees have easy access to management areas. Setting up a multifunctional utility room nearby that includes electricity, water and supplies is a great way to improve worker efficiency, as they don’t have to leave the sort area to get what they need. Additionally, plan for machinery access (i.e., skid steer or small tractor) to the post-milking management area in case of emergencies.
Step 2: The importance of cow flow
Each sort system should allow for continuous, even-paced cow flow. Cow traffic should proceed through the gates at a relaxed pace no matter the rotary speed. If cows are rushing, they are more likely to slip, fall or escape the sort. On the contrary, cows moving too slow or hesitating to pass through the sort system can cause traffic problems and pose an additional risk.
When sorting a large number of cows for management, ensure enough employees are in the post-milking sort area to keep them moving through palpation rails, hoof trim areas or other general management holding zones. If cows aren’t processed quickly, traffic will back up within the sort lanes and cause stress for cows and employees. The goal is to minimize instances where the rotary needs to stop turning to allow for cow traffic to clear through the sort area.
Step 3: Setting sort system expectations
Sort system design varies based on expectations and usage. Determine the needs and design accordingly. Here are some common reasons to sort cows and the associated equipment that may make management easier for employees:
- Breeding, including timed A.I. protocols: Extensive reproductive management may require palpation rail installation.
- Herd health checks, vaccinations and medical attention: Safely doctoring animals often requires a squeeze chute or headlocks in a designated post-milking holding pen.
- Hoof trimming: In-house trimming is made easier by a spacious trimming station.
Remember, sort areas may require access to feed and water based on the anticipated amount of time cows will spend there.
A well-designed sort system can significantly boost the efficiency and safety of a rotary parlor’s post-milking area. By focusing on streamlined design, effective cow flow and adequate worker processes, it is possible to ensure the system meets both current and future cow management needs.
Sort system management tips
Outside of routine maintenance and software updates, it never hurts to have a short checklist of easy tasks to ensure efficient use and operation of the sort system. Here are a few basic suggestions to help get the most out of the sort system:
- Clean sensors on the gates responsible for identifying cows daily (i.e., photocells and ID readers).
- Flush or hose out flooring in and around sort gates after each milking session to maintain good traction.
- Check that sort gates open and close quickly without slamming shut.
- Implement good RFID tag management; change dead or failing tags or collars routinely.
- Do not let cows bypass the sort gates unless there is an emergency. If they learn that passing through the gates is optional, cow flow can be compromised.
- Have a posted standard operating procedure for downed cows in the sort areas so employees act quickly and effectively.
