Mark W. Mayer, Dairy & LivestockMark W. Mayer, Dairy & LivestockAgent, Green CountyAgent, Green County

David W. Kammel, Biological David W. Kammel, Biological Engineering, UW-MadisonEngineering, UW-Madison

Wisconsin Dairy Wisconsin Dairy Modernization Survey Modernization Survey

UW-Extension UW-Extension 20082008

30 Counties 30 Counties RepresentedRepresented

104 Surveys 104 Surveys ReceivedReceived

99 Surveys In Data 99 Surveys In Data SetSet

General Farm InformationGeneral Farm Information

PrePreModernizationModernization

Post Post ModernizationModernization

Herd Size (Milk Cows) 82 203

Average Milk Production /Cow

19,601 lbs. 20,941 lbs.

Acres of Land Owned 351 421

Acres of Land Rented 187 308

Acres/Cow (owned & rented) 6.56 3.59

Full Time Labor Equivalents for Dairy

2.34 4.32

Milk Cows per F.T.E. 35 50

Parlor Construction &TypeParlor Construction &TypeMilking Stall Type

8

11

40

30

2Flat Barn Herringbone Parabone Parallel Rotary

n = 91

New vs. UsedNew vs. Used

n = 89 n = 91

Labor for ParlorLabor for Parlor

Labor Supplied for Parlors

37%63%

Farmer Contractor Average Time For Parlor Conversion:

17 weeks17 weeks

Range of Time to Convert: Range of Time to Convert:

4 to 104 Weeks 4 to 104 Weeks

Labor Provided for ParlorLabor Provided for ParlorNew Construction vs. RetrofitNew Construction vs. Retrofit

New Parlors

24%

76%

Farmer Contractor

Retrofit Parlors

45%55%

Farmer Contractor

Time for Parlor Conversion Time for Parlor Conversion Construction Time

Weeks

0

5

10

15

20

4 8 12 16 20 24 28 32 36 40 44 48 52 104Weeks

Freq

uenc

y

Parlor Construction &TypeParlor Construction &Type

R etrofit C ons truc tion S tall T ype

6

8

30

11

F lat B arnHerringboneP araboneP arallel

New C ons truc tion S tall T ype

3

10

18

3

HerringboneP araboneP arallelR otary

n = 55 n = 34

Parlor Cost per Milking StallParlor Cost per Milking Stall2008 Dollars2008 Dollars

ParlorStall Type

RetrofitConstruction (n=55)

New Constructionn= 34

Flat barn $3,360(n=6)

NA

Herringbone $9,657(n=8)

$18,769(n=3)

Parabone $3,845(n=30)

$6,016(n= 10)

Parallel $7,478(n=11)

$22,361(n=18)

Cow Housing FacilityCow Housing Facility

6

21

1911

1

164

2 row FS barn

3 row FS barn

4 row FS barn

6 row FS barn

8 row FS barn

Bedded pack barn

Compost bedded barn

n = 78

Manure Handling and StorageManure Handling and Storage

Manure Handling System

1

811

87

Skid Steer /Tractor ScrapeAutomatic ScraperFlushOther

Manure Storage

31

2952

Daily Haul

Short Term Storage

Long Term Storage

n = 107 n = 112

Manure Storage and BeddingManure Storage and Bedding

n = 77

n = 101

Replacement HousingReplacement Housing

n = 101 n = 86

Economic InvestmentEconomic InvestmentSince 1993 (2008 Dollars)Since 1993 (2008 Dollars)

• Milking Parlor Facility– $17,144,281

• Dairy Cow Housing– $30,529,855

• Dry Cow Housing– $1,722,057

• Heifer Housing– $1,610,210

• Calf Housing– $1,480,703

• TMR Feeding– $1,981,566

• Feed Storage– $4,153,360

• Manure handling– $2,149,120

• Manure Storage– $4,536,318

• Total Investment for 99 Total Investment for 99 farms in Survey $65,307,470farms in Survey $65,307,470

Dairy Modernization ImpactsDairy Modernization ImpactsPreModernization

Post Modernization

Change

Milk Cows 7,923 19,689 +11,766

Ave. Herd Size 82 203 +121

Total Annual Milk Production

160,401,113 (lbs)

426,936,276 (lbs) +266,535,163

Ave. Production per Cow (lbs)

20,245 21,684 +1,439

Dry Cows 1,197 2,920 +1,723

Heifers 4,307 10,207 +5,900

Calves 2,320 5,868 +3,548

Modernization Economic Impacts Modernization Economic Impacts

ChangeChange Dollar ImpactDollar Impact

Average Increased Milk Income per Cow

+1,439 lbs x $17/cwt

= $245

Ave. Increased Gross Milk Income per Farm

203 cows @ 21684 x .17= $748,315 82 cows @ 20245 x .17 =- $282,215

= $466,099

Increased Local Economic Impact from more cows/farm

121 cows x **$17,000 = $2.06 Million

Increased Annual Milk Income for the State

+266,535,163 lbs. x 99 farms x $.17

= *$44.8 Million

Economic Impact from more Cows in the State

+11,766 cows x $17,000 = *$200 Million

* Total for 99 Herds**UW Department of Agriculture and Applied Economics

Milking System ThroughputMilking System Throughput

0

5

10

15

20

25

0 10 20 30 40 50 60 70 80 90 100 110Cows Milked/Person/Hour

Freq

uenc

y

PRE

POSTMean = 44.1 cows/person/hour Std Dev = 19.79

Mean = 22.7 cows/person/hour Std Dev =11.56

Change = 21.4 cows/person/hour

P = 0.000

Pre and Post Labor Requirements Pre and Post Labor Requirements Average Per Cow/DayAverage Per Cow/Day

1.59

0.65 0.72

0.49

0.79

0.4

0

1

2

Min

utes

/Cow

/Day

**Feeding Milk Cows *Handling Cows **Handling Manure

Pre Modernization

Post Modernization

**P= <.001 *P= <.01

Pre and Post Labor Requirements Pre and Post Labor Requirements Average Per Cow/DayAverage Per Cow/Day

4.07

2.09

0.80.32 0.51 0.32

00.5

11.5

22.5

33.5

4

Min

utes

/Cow

/Day

**Milking **Maintaining Stalls *Milking Setup/Cleanup

Pre Modernization

Post Modernization

**P= <.001 *P= <.01

Reduced Labor Requirements Reduced Labor Requirements Minutes Per Minutes Per Cow / DayCow / Day

Total Reduction Total Reduction Per Cow / Year Per Cow / Year

Milking Setup/Cleanup .19 x 365 =1.16 hours

Milking Time 1.98 x 365 =12.05

Feeding Time per Cow .94 x 365 = 5.72 hours

Handling Cows .26 x 365 = 1.58 hours

Maintaining Stalls .48 x 365 = 2.92 hours

Handling Manure .39 x 365 = 2.37 hours

Totals: 4.24 minutes/Day 25.80 hours/Year

Economic Impacts from Reduced Economic Impacts from Reduced Labor Per Cow Labor Per Cow

Reduction/Cow/YearReduction/Cow/Year Dollar ImpactDollar Impact

Milking Setup/Cleanup 1.16 hours @ $12/Hour =$13.92

Milking Time 12.05 hours @$12/Hour =144.60

Feeding Time per Cow 5.72 hours @ $12/Hour = $68.64

Time Handling Cows 1.58 hours @ $12/Hour = $18.96

Maintaining Stalls 2.92 hours @ $12/Hour = $35.04

Handling Manure 2.37 hours @ $12/Hour = $28.44

Totals: 25.80 Hours/Cow/Year $309.60/Cow/Year

Cow Benefits ObservedCow Benefits Observed

66%

73%

74%

78%

82%

85%

Increase ConceptionRates

Lower Culling Rate

Increased Production

Lower SCC

Less Feet & LegProblems

Overall Cow Health

Ranking of Cow BenefitsRanking of Cow Benefits

4.27

4.34

4.53

4.58

4.65

4.86

3 3.5 4 4.5 5 5.5 6

Increase ConceptionRates

Increased Production

Lower SCC

Lower Cull Rate

Less Feet & Leg Problems

Overall Cow Health

Less Important More Important

People Benefits ObservedPeople Benefits Observed

78%

80%

82%

86%

88%

93%

96%

Increased Family Time

Provided Entry for NextGeneration

Increased Profitability

Allowed Business toContinue

Improved Health/Safetyof Workers

Improved WorkingConditions for Milkers

Reduced Labor Per Cow

Ranking of People BenefitsRanking of People Benefits

4.61

4.85

4.92

5.1

5.13

5.16

5.26

3 4 5 6

Increased Family Time

Increased Profitability

Reduced Labor PerCow

Provided Entry forFuture Generation

Allowed Dairy toContinue

Improved Health andSafety for Workers

Improved WorkingCondition for Milkers

Educational Resources Used Educational Resources Used

46%

64%

65%

67%

73%

81%

86%

86%

99%

Phone/Email StateSpecialist

Phone/EmailCountyAgent

U.W. Publications,Newsletters, CD's

Farm Shows

Farm Visit by UWState Specialist

Magazines andNewspapers

Farm Visit byCounty Agent

ExtensionMeetings/Seminars

Visiting OtherFarms/Tours

Ranking of Educational ResourcesRanking of Educational Resources

4.12

4.42

4.52

4.62

5.48

3.94

3.91

4.00

3 3.5 4 4.5 5 5.5 6

Magazines and Newpapers

Farm Shows

UW Publications and CD's

Phone/Email to State Specialist/Co Agent

U.W. Seminars and Meetings

Farm Visit by County Agent

Farm Visit by UW State Specialist

Visiting Other Farms/Tours

Professional Resources Used Professional Resources Used

30%

33%

64%

66%

76%

85%

86%

89%

93%

Professional Design Consultant

Financial Consultant

Nutritionist

Veterinarian

Ag Lender

Builder/Contractor

Other Dairy Producers

Milk Equipment Dealer

UW-Extension Agent/Specialist

Ranking of Professional ResourcesRanking of Professional Resources

4.36

4.52

4.53

4.57

4.73

4.78

4.00

3.53

4.03

3 3.5 4 4.5 5 5.5 6

Professional Design Consultant

Veterinarian

Financial Consultant

Milk Equipment Dealer

Nutritionist

UW-Extension Agent/Specialist

Ag Lender

Builder/Contractor

Other Dairy Producers

UW-Extension Impacted Decisions UW-Extension Impacted Decisions with Dairy Modernization with Dairy Modernization

22%

78%

Yes

No

n = 99

Average Planning Time: 23.02 Months

Range: 3-120 Months

How Did UW-Extension Help?How Did UW-Extension Help?(27) Assisted in Parlor Location and Design

(20) Organized Tours and Farm Visits to Observe Modernization on other Farms

(15) Presented new Ideas and Options for Parlor Design and Construction

(12) Design and Layout of Cow Housing Including Cow Flow and Stall size

(9) UW-Extension Dairy Modernization Presentations (Meetings and Pasture Walks)

(5) UW Publications (Low Cost Parlor CD and Retrofit Parlor Paper)

(5) Received reinforcement of ideas and plans

(4) Assisted in the Permitting Process

(4) Assisted in Preparing Budget for Modernization Project

(3) Assisted in Manure Handling and Storage plans

(3) County Agents and State Specialists answered all our questions

(3) Assistance with Ventilation

117 Responses

How Could Assistance from UW-How Could Assistance from UW-Extension be Improved ?Extension be Improved ?

3222

87

3Don't Know/ No ResponseWere so HelpfulKeep Doing what your doingBring real life dairy experience More awareness of expanding dairies in the areaWork with NRSC and Government to speed up grant processes

n = 99

Biggest Challenge in ModernizationBiggest Challenge in Modernization(16) Working with the Contractors/Serving as General Contractor

(10) Deciding what system & number of cows would work best for my farm

(10) Budgeting & Financing for Expenses

(8) Milking in Existing Facilities During Construction

(8) Design of Milking Facility & Housing

(6) Cost Over runs

(5) Finding Good & Knowledgeable Contractor

(4) Manure Storage & Handling

(4) Confidence & Motivation to do it

(3) Permitting Process for Building/Expanding

(3) Getting Honest Opinions from Equipment Dealers

(3) Did too much of my own labor

(3) Changing the Management System of Feeding/Breeding/Housing

What Would You Change?What Would You Change?

(14) Wish we would have done the expansion sooner.

(11) Wish we would have made the parlor/freestalls bigger

(6) Start expansion at another site to allow for additional future expansions

(5) Spend more time planning and seeking help in design

(4) Start with new building and equipment right away

(4) Would not start building in the fall, start earlier in the year

(4) Design of Parlor

(3) Add a dry cow and calving facility

(3) Change from mattresses to sand for bedding

(3) Hire a more experienced and honest contractor

Would You Still be in the Dairy Would You Still be in the Dairy Business if you had not Business if you had not

Modernized?Modernized?

54%46%

Yes No n = 94

Programs and Grants UtilizedPrograms and Grants Utilized

2

2

4

5

5

8

13

27

27

30

0 5 10 15 20 25 30 35

Number of Producers

Questions!