SNV Professional Cow House Design PDF

Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.
com
CONTENTS
SNV/KENYA, NETHERLANDS
DEVELOPMENT ORGANISATION
LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
KENYA MARKET-LED DAIRY
PREAMBLE ................................................................................................................................................ 05
PROGRAMME
CHAPTER 1: INTRODUCTION (KMDP) .............................................................................................................. 07
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.1
2.2 HANDBOOK
ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08
DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09
2.3 DAIRY COW HOUSE DESIGN ................................................................................................................ 10
2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13
2.6 TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................ 16
3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour ............................................................................................. 17
3.2.2. Manure Storage/Waste Water Storage................................................................................... 18
3.2.3. Waiting Area (Holding Pen) .................................................................................................. 19
3.2.4. Treatment/Handling of Cows ................................................................................................. 19
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20
3.2.7. Special Needs Cows ................................................................................................................ 21
3.2.8. Grouping of Young Stock ....................................................................................................... 21
3.2.9. Water Supply.......................................................................................................................... 21
3.2.10. Essential Points to Consider for each Module ........................................................................ 22
3.2.11. Management to Increase Number of Cows............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.2. Schedule for Barn Inspection Rounds .................................................................................... 27
DESIGNING AND PLANNING MODULAR
3.4.3. Week-planning........................................................................................................................ 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................ 29
DAIRY
3.6 COW HOUSE (KENYA)
TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4.1 COW HOUSE CONSTRUCTION COSTS .................................................................................................. 34
4.1.1. Construction Costs Cow House Modules 1-4 ........................................................................ 34
4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT ........................................................................................................................... 35
4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36
4.4 FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37
4.5 MANURE PRODUCTION AND STORAGE ............................................................................................... 39
4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40
4.7 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
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Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.com
CONTENTS
CONTENTS
LIST OF TABLES ......................................................................................................................................... 03

LIST OF TABLES ......................................................................................................................................... 03
ABBREVIATIONS ....................................................................................................................................... 04
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
PREAMBLE ................................................................................................................................................ 05
CHAPTER 1: INTRODUCTION .............................................................................................................. 07
2.1 ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08
2.1 D
2.2 AAIRY
CCESSFTO
ARM PUBLIC
LAY-OUT UTILITIES
PRINCIPLES...............................................................................................................
..................................................................................................... 08
09
2.2
2.3 DAIRY F CARM
OW H LOUSE
AY-OUT PRINCIPLES
DESIGN ..................................................................................................... 09
................................................................................................................ 10
2.3
2.4 D AIRY COW
EXAMPLE HOUSEOF
LAYOUT DM ESIGN
ODULAR ................................................................................................................
DAIRY COW HOUSE ...................................................................... 10 12
2.4 E L M D C H ......................................................................
XAMPLE AYOUT OF ODULAR AIRY OW OUSE 12
2.5
2.6 S YPICAL FFARM
TUPPORT LAYOUT
UNCTIONS AND AND PHYSICAL
FENCING STRUCTURES ........................................................................... 13
.............................................................................................. 15
3.1 MODULAR
3.2 ANAGEMENT FARM OFDM ODULAR FARM
EVELOPMENT ........................................................................................................
DEVELOPMENT PLAN .............................................................. 16 17
3.2 M3.2.1. M F D P ..............................................................
Capacity of the Milking Parlour .............................................................................................
ANAGEMENT OF ODULAR ARM EVELOPMENT LAN 17
3.2.1.
3.2.2. Capacity of the Milking Water
Manure Storage/Waste Parlour .............................................................................................
Storage ................................................................................... 17
18
3.2.2.
3.2.3. Manure
Waiting Storage/Waste
Area (Holding Water Storage................................................................................... 18
Pen) .................................................................................................. 19
3.2.3.
3.2.4. Waiting Area (Holding Pen) ..................................................................................................
Treatment/Handling of Cows ................................................................................................. 19
3.2.4.
Milk Storage ...........................................................................................................................
3.2.5.
3.2.6. Milk
Cows:Storage ...........................................................................................................................
Milk Production and Dimensions ............................................................................... 19 20
3.2.6.
3.2.7. Cows:
SpecialMilkNeeds Production and Dimensions ............................................................................... 20
Cows ................................................................................................................ 21
3.2.7.
3.2.8. Special
Grouping Needs Cows Stock
of Young ................................................................................................................
....................................................................................................... 21
3.2.8.
3.2.9. Grouping
Water Supply of Young Stock ....................................................................................................... 21
..........................................................................................................................
3.2.9.
3.2.10. Water
EssentialSupply
Points ..........................................................................................................................
to Consider for each Module ........................................................................ 21 22
3.2.10.
3.2.11. Essential
Management Points to Consider
to Increase Numberfor each Module
of Cows ........................................................................ 22
.............................................................................
3.3 D3.2.11.
ESIGN OF FLOORS AND
Management to CIncrease
UBICLES .....................................................................................................
Number of Cows............................................................................. 22 23
3.3 D F C .....................................................................................................
3.4 FEED FENCE ........................................................................................................................................... 26
ESIGN OF LOORS AND UBICLES 23
3.4 F EED FENCE
3.4.1. ...........................................................................................................................................
Breeding Bull(s) ...................................................................................................................... 26
3.4.1.
3.4.2. Breeding
Schedule for Bull(s)
Barn ......................................................................................................................
Inspection Rounds .................................................................................... 26 27
3.4.2.
3.4.3. Schedule for Barn Inspection Rounds ....................................................................................
Week-planning........................................................................................................................ 28 27
3.5 3.4.3. AND BIOSECURITY
HYGIENEWeek-planning ................................................................................................................ 29
........................................................................................................................ 28
3.5 T
3.6 HREATMENT
YGIENE AND ANDBIOSECURITY
HANDLING................................................................................................................
DAIRY CATTLE .................................................................................... 29 32
3.6 TREATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
4.1 C OW HOUSE
4.1.1. CONSTRUCTION
Construction Costs Cow COSTS House ..................................................................................................
Modules 1-4 ........................................................................ 34
4.1.1.
4.1.2. Construction
Biogas Digester Costs Cow House Modules 1-4 ........................................................................ 34
....................................................................................................................... 35
4.2 4.1.2.
HERD DEVELOPMENT
Biogas Digester ...........................................................................................................................
....................................................................................................................... 35
4.2 M
4.3 HERD
ILK PDRODUCTION
EVELOPMENT AND...........................................................................................................................
MILK STORAGE ........................................................................................... 35 36
4.3
4.4 MFEED PRODUCTION
ILK AND FEED STORAGE AND M RILK STORAGE ...........................................................................................
EQUIREMENTS ......................................................................................... 36
37
4.4
4.5 FMEED
ANUREANDPFRODUCTION
EED STORAGE AND REQUIREMENTS ......................................................................................... 37
STORAGE ............................................................................................... 39
4.5
4.6 MOTHER
ANURE PRODUCTION
FARM BUILDINGS ANDAND STORAGE
STORAGES ...............................................................................................
.......................................................................................... 39
40
4.6
4.7 O THER FARM
SUMMARY FARM BUILDINGS
STRUCTURE ANDM STORAGES
EASUREMENTS ..........................................................................................
................................................................................. 40
41
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CONTENTS
LIST OF TABLES ......................................................................................................................................... 03

CHAPTER 5: PLANNING AND IMPLEMENTATION.......................................................................42
ABBREVIATIONS ....................................................................................................................................... 04
5.1 CONCEPT PLAN ..................................................................................................................................... 42
PREAMBLE ................................................................................................................................................ 05
5.2 BUSINESS PLANNING AND FINANCIAL FEASIBILITY ........................................................................... 45
CHAPTER
5.3 1: INTRODUCTION
PREPARATION AND PLANNING ..............................................................................................................
FOR IMPLEMENTATION .................................................................... 46 07
5.4 IMPLEMENTATION
CHAPTER 2: STRUCTURES,OF CONSTRUCTION WORKS .................................................................................. 48
CONSIDERATIONS AND IMPLICATIONS ................................. 08
5.5 FARM MANAGEMENT AND TRAINING ................................................................................................ 48
ANNEX 1: BEST AND WORST PRACTICES......................................................................................... 49
2.2 DAIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09
2.3 DAIRY
ANNEX COW HOUSE D
2: SCENARIOS HERD ................................................................................................................
ESIGN NUMBERS AND TREATMENT SCHEDULE.............................. 10 61
ANNEX 3: 3D PRESENTATIONS AND TECHNICAL DESIGN DRAWINGS .............................. 72
ANNEX
2.6 4: BILL
TYPICAL OF L
FARM QUANTITIES
AYOUT AND FENCING MODULAR COW HOUSE.......................................................... 15
.............................................................................................. 94
ANNEX 5: BILL
CHAPTER OF QUANTITIES
3: CATTLE BIOGASAPPROACH
BARN MODULAR AND OPERATIONS ............................103
INSTALLATION........................................................ 16
ANNEX 6: FEEDFREQUIREMENT
3.1 MODULAR ARM DEVELOPMENT ..........................................................................................................
........................................................................................................107
16
3.2 M ANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
ANNEX 7: GOVERNMENT CONSTRUCTION REGULATIONS .................................................. 110
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.9. Water Supply.......................................................................................................................... 21
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester ....................................................................................................................... 35
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CONTENTS
LIST OF TABLES
Table 1. Number of clusters needed to milk all cows in 1 hour and 15 minutes:...................... 18
Table 2. Milk production per day as input to decide milk tank capacity ................................... 19
Table 3. Attention list cow characteristics ....................................................................................... 20
LIST
Table OF
4. TABLESRain.........................................................................................................................................
water collection and usage ........................................................................................ 22 03
Table 5.
ABBREVIATIONS Example of rain water collected (Litres) ........................................................................... 22
....................................................................................................................................... 04
Table 6. Barn inspection round schedule ........................................................................................ 28
PREAMBLE
Table 7. ................................................................................................................................................
Milk-room facilities and requirements ............................................................................. 30 05
Table 8.
CHAPTER Separate (room) structures
1: INTRODUCTION typical measurements (indicative m2)............................... 31
.............................................................................................................. 07
Table 9. Approximate cow house construction costs in Kenyan Shillings (KES) ...................... 34
Table 10. Biogas estimated construction cost ................................................................................... 35
Table
2.1 A 11.
CCESS TO PUBLIC
Herd UTILITIES ...............................................................................................................
development (established situation) ....................................................................... 36 08
2.2
Table D AIRY FARM
12. MilkLProduction
AY-OUT PRINCIPLES (indicative) ..................................................................................................... 09
.............................................................................................. 36
2.3
Table D AIRY COW
13. HOUSE
Typical DESIGNof................................................................................................................
example a feed ration ....................................................................................... 37 10
Table E14.
2.4 XAMPLEMaize
LAYOUT silage
OF M bunker
ODULAR measurements
DAIRY COW H(without soil cover) .............................................. 38
OUSE ...................................................................... 12
Table S15.
2.5 UPPORT Hay storageAND
FUNCTIONS capacity
PHYSICAL...........................................................................................................
STRUCTURES ........................................................................... 39 13
Table T16.
2.6 YPICAL FManure
ARM LAYOUT production AND Fper ENCINGannum ......................................................................................... 39
.............................................................................................. 15
Table 17. Manure storage (used as fertiliser) .................................................................................... 40
Table 18. Farm structures measurements (summary) indicative in metres ................................. 41
3.1
Table M19.ODULAR FARM D
Cement material
EVELOPMENT ........................................................................................................
requirement for concrete flatwork ......................................................51 16
3.2 M
Table 20. M F D P ..............................................................
Total construction costs (summary Bill of Quantities) ................................................... 102
3.2.2.
LIST OF FIGURES Manure Storage/Waste Water Storage................................................................................... 18
3.2.3.
Figure 1. Waiting
Barn Area(side
design (Holding view) Pen) ..................................................................................................12
....................................................................................................... 19
Figure3.2.4.
2. Treatment/Handling
Barn layout (top view of Cows
40 cows .................................................................................................
module) ........................................................................... 13 19
3.2.5.
Figure 3. Milk Storage ...........................................................................................................................
General farm layout............................................................................................................. 15 19
3.2.6.
Figure 4. Cows: Milk Production and Dimensions ...............................................................................
Week Calendar and White Board ...................................................................................... 29 20
3.2.7.
Figure 5. Special Needs Cows ................................................................................................................
Cow house modular design with 20 cows per module .................................................. 35 21
Figure 6. Wet concrete floors .............................................................................................................. 53
3.2.9. Water Supply.......................................................................................................................... 21
Figure 7. Flat concrete floors............................................................................................................... 53
Figure 8. Sloped floors ......................................................................................................................... 53
Figure 8b. Sloped floors ......................................................................................................................... 54
Figure 9. Dry concrete floors .............................................................................................................. 54
3.4 FEED FENCE ........................................................................................................................................... 26
Figure 10. Grooves ................................................................................................................................. 54
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
Figure 11. Longitudinal grooves .......................................................................................................... 55
Figure 12. Uneven floors ....................................................................................................................... 55
3.4.3. Week-planning........................................................................................................................ 28
Figure
3.5 H13. Floors and support posts (1)............................................................................................... 56
YGIENE AND BIOSECURITY ................................................................................................................ 29
Figure
3.6 T14. Roof design ........................................................................................................................... 56
REATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
Figure 15. Floors and support posts (2)............................................................................................... 57
CHAPTER
Figure 16. 4: COST and
Floors CALCULATIONS
posts distances FOR THE MODULAR BARN DESIGN .......................... 57
.................................................................................................. 34
Figure
4.1 C17.OW HOUSECorrectly positionedCfeed
CONSTRUCTION OSTSfence ......................................................................................... 58
.................................................................................................. 34
Figure4.1.1.
18. Wrongly positioned feed fence ..........................................................................................
Construction Costs Cow House Modules 1-4 ........................................................................ 34 58
Figure4.1.2.
19. Swedish
Biogas Digesterfeed fence .............................................................................................................. 59
....................................................................................................................... 35
Figure 20. Swedish feed fence from wood .......................................................................................... 59
FigureM21.
4.3 Feed fences
ILK PRODUCTION ANDfor M young stock ...............................................................................................
ILK STORAGE ........................................................................................... 59
36
Figure 22. Cleaning of feed troughs .................................................................................................... 37
FigureM23.
4.5 ANUREScreenshot
PRODUCTION AnnexAND 3.c 3D 80 Cows
STORAGE module steel feed rail.............................................. 74
............................................................................................... 39
Figure 24. Annex 3.e TD Farm layout .................................................................................................
4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 77
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CONTENTS
ABBREVIATIONS
°C Degrees Celsius
BC Building Company
LIST
BCS OF TABLES Body.........................................................................................................................................
Condition Score 03
BLV
ABBREVIATIONS Bovine Leukaemia Virus
....................................................................................................................................... 04
BOQ Bill of Quantities
PREAMBLE
BVD ................................................................................................................................................
Bovine Virus Diarrhoea 05
CBE
CHAPTER Milk Collection and..............................................................................................................
1: INTRODUCTION Bulking Enterprise 07
CC Coliform Count
CHAPTER
CFP 2: STRUCTURES,
Commercial Fodder CONSIDERATIONS
Producer AND IMPLICATIONS ................................. 08
Cfu ACCESS TO
2.1 Colony
PUBLIC Forming
UTILITIES Unit............................................................................................................... 08
CIP DAIRY FARM
2.2 Cleaning
LAY-OUT In-Place
PRINCIPLES ..................................................................................................... 09
DTI DAIRY COW
2.3 DairyHOUSETrainingDESIGN Institute
................................................................................................................ 10
EIA EXAMPLEEnvironmental
2.4 LAYOUT OF MODULAR Impact D Assessment
AIRY COW HOUSE ...................................................................... 12
EUR Euro
FMD
2.6 TYPICAL FFoot ARMand LAYOUTMouth AND Disease
FENCING .............................................................................................. 15
Ha Hectare
IBR Infectious Bovine Rhinotracheitis
3.1 MODULAR
KES FARM D
Kenyan EVELOPMENT ........................................................................................................ 16
Shilling
3.2 MANAGEMENT
KMDP Kenyan MODULAR Dairy
OFMarket-led FARM D EVELOPMENT PLAN .............................................................. 17
Programme
kW 3.2.1. Kilowatt
Capacity of the Milking Parlour ............................................................................................. 17
LPD 3.2.2. Litres
Manure per Day
Storage/Waste Water Storage................................................................................... 18
Lt 3.2.3. Litre
Waiting Area (Holding Pen) .................................................................................................. 19
MCP 3.2.4. Treatment/Handling
Milk Collection Point of Cows ................................................................................................. 19
MSF 3.2.5. Milk Storage
Medium Scale...........................................................................................................................
Farmer 19
Neg. 3.2.6. Cows:
Negative Milk Production and Dimensions ............................................................................... 20
NEMA 3.2.7. Special Needs Cows ................................................................................................................
National Environment Management Authority 21
Pos. 3.2.8. Grouping of Young Stock ....................................................................................................... 21
Positive
QA 3.2.9. Water Supply
Quality .......................................................................................................................... 21
Assurance
QC 3.2.10. Essential
Quality Controlto Consider for each Module ........................................................................ 22
Points
Management to Increase Number of Cows............................................................................. 22
Qnt 3.2.11. Quantity
3.3
RVF D ESIGN OF FLOORS
Rift ValleyAND Fever CUBICLES ..................................................................................................... 23
3.4
SCC FEED FENCE ...........................................................................................................................................
Somatic Cell Count 26
SNV 3.4.1. Breeding Bull(s) ......................................................................................................................
Netherlands Development Organisation 26
SOP 3.4.2. Schedule for Barn
Standard Operating Procedure Inspection Rounds .................................................................................... 27
3.4.3. Week-planning........................................................................................................................ 28
SS Stainless Steel
t.b.d. To be decided
Tn Tonnes (weight)
TPC
CHAPTER Total Plate
4: COST Count
CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
UHT Ultra High Temperature (treated milk)
USD United States Dollars
4.1.2. Biogas Digester ....................................................................................................................... 35
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CONTENTS
PREAMBLE
This Handbook has been prepared for the Kenya Market-led Dairy Programme (KMDP) by
LIST TABLES .........................................................................................................................................03
OF(www.vetvice.com)
Vetvice and The Friesian Dairy Development Company (www.thefriesian.nl).
Both companies are.......................................................................................................................................04
ABBREVIATIONS based in the Netherlands and operate worldwide as consultants and trainers
in cow house design and dairy management. In Kenya they were assisted by Perfometer
PREAMBLEfrom
Consultants ................................................................................................................................................05
Nairobi and Eldosirikwa Consultants from Eldoret.
CHAPTER 1: INTRODUCTION ..............................................................................................................07
KMDP is a 4.5 year programme funded by the Embassy of the Kingdom of the Netherlands in
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS .................................08
Nairobi. The programme started 1st of July 2012 and is implemented by SNV/Kenya, Netherlands
2.1 ACCESS TO
Development PUBLIC UTILITIES
Organisation, ...............................................................................................................08
in collaboration with stakeholders in the Kenyan dairy industry.
2.2 D FARM L AY - OUT P RINCIPLES .....................................................................................................09
SNV is an international not-for-profit development organisation founded in the Netherlands
AIRY
2.3 D50
nearly AIRY COWago.
years HOUSE SNV DESIGN ................................................................................................................
has offices and programmes in 36 countries in Asia, Africa and Latin 10
2.4 EXAMPLE
America (see forLAYOUT OF MODULAR
more information at D AIRY COW HOUSE ...................................................................... 12
www.snvworld.org).
2.6 TYPICAL
KMDP (KMDPFKenya)
ARM LAYOUT stimulatesAND F best
ENCING ..............................................................................................
practices and facilitates transfer of knowledge and skills, for 15
enhanced
CHAPTERcompetitiveness
3: CATTLE BARN of theMODULARdairy industry APPROACH in Kenya. ANDThe overall goal............................
OPERATIONS of KMDP is 16 to
contribute to the development of a vibrant growth-oriented and private sector-driven dairy
3.1 MODULAR
industry, FARM DEVELOPMENT
with beneficiaries across the ........................................................................................................
value chain. It works around two pillars or strategic 16
3.2 M ANAGEMENT
intervention levels: OF M ODULAR F ARM D EVELOPMENT P LAN .............................................................. 17
3.2.1. Capacity of the Milking Parlour............................................................................................. 17
I. Smallholder Manure
3.2.2. dairy value Storage/Waste
chain Water Storage................................................................................... 18
KMDP works with 4 processors andPen)
3.2.3. Waiting Area (Holding ..................................................................................................
16 dairy societies across Kenya’s major milk sheds, who are 19
3.2.4.
willing Treatment/Handling
to invest in farmers’ training of Cows.................................................................................................
& extension, milk quality, enhanced input and service 19
3.2.5. Milk Storage ...........................................................................................................................
provision and improved governance and business management. 19
3.2.7.
II. Dairy sectorSpecial
systemic NeedsissuesCows ................................................................................................................ 21
Under this pillar KMDP facilitates innovations, transfer of technology, knowledge & skills, and
3.2.9. Water Supply.......................................................................................................................... 21
(international) investments that help spur transitioning the dairy sector structure, including the
3.2.10. Essential Points to Consider for each Module........................................................................ 22
infrastructure for services and training. Here KMDP works with medium and large scale
commercial dairy farms (MSF Model), commercial fodder producers and supply chains (CFP
Model), and processors willing to pilot a quality based milk payment system. In addition to this,
3.4 FEED FENCE ........................................................................................................................................... 26
KMDP supports initiatives for commercialisation of training for practical skills development,
3.4.1. Breeding Bull(s)...................................................................................................................... 26
through its engagement with DTI Naivasha and Practical Dairy Training Farms or Centres located
close to the farmer. Finally KMDP stimulates and facilitates business-to-business linkages and
3.4.3. Week-planning........................................................................................................................ 28
partnerships
3.5 HYGIENEbetween stake-holders in the Kenyan dairy industry and Dutch (and other
AND BIOSECURITY ................................................................................................................ 29
international) input
3.6 TREATMENT AND HANDLINGsuppliers, service
DAIRY providers, knowledge institutes and investors.
CATTLE .................................................................................... 32
CHAPTER
The activities4: under
COSTLevelCALCULATIONS
II are geared towardsFOR THE MODULAR
dairy BARN DESIGN
sector transitioning and KMDP ..........................
has singled 34
out
4.1 the
COW steady growing
HOUSE group of emerging
CONSTRUCTION Medium Scale commercial dairy Farmers (MSFs), as34a
COSTS ..................................................................................................
target group
special4.1.1. for support.
Construction ThisHouse
Costs Cow segment of farmers
Modules is viewed by KMDP as crucial for sector
1-4 ........................................................................ 34
transformation
4.1.2. and food security in the long term, due to their interest and ability - in terms 35
Biogas Digester....................................................................................................................... of
land and capital - to invest and innovate in professional dairy farming.
Besides,
4.3 MILK it P
isRODUCTION
assumed that ANDifMthese MSFs are
ILK STORAGE capacitated to grow and to improve their dairy
........................................................................................... 36
farming practices, this will have important positive spill-over to the smallholder supply chain; for
example
4.5 MANURE as regards to fast-tracking
PRODUCTION the development
AND STORAGE of an effective dairy service infrastructure. 39
...............................................................................................
KMDP support is
4.7 SUMMARY focused
FARM on organisation
STRUCTURE of MSFs.................................................................................
MEASUREMENTS in platforms and study groups and training on 41
Total Farm Management, incl. fodder management, cow house design and farm record keeping.
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CONTENTS
KMDP is implementing a special demonstration project on farm record keeping with 10 demo
farmers in North Rift, Central and Eastern. This Handbook is concerned with cow house design.
The Handbook is developed especially for MSFs who intend to invest in the establishment of a
LIST OF TABLES
new dairy .........................................................................................................................................
farm enterprise, or who wish to upgrade or expand their existing dairy production 03
facilities. In particular
ABBREVIATIONS this Handbook will be of use to Dairy Consultants and Architects 04
....................................................................................................................................... in
advising and guiding MSFs on farm planning and cow house design.
PREAMBLE ................................................................................................................................................ 05
The main objective
CHAPTER of the Handbook
1: INTRODUCTION is therefore to guide farmers/investors – and their advisors07-
..............................................................................................................
on professional and cost effective methods of developing their dairy farm, by following a
CHAPTERand
structured 2: STRUCTURES,
planned approach. CONSIDERATIONS
In the Handbook emphasis AND IMPLICATIONSis on the design.................................
of the cow house 08 or
cattle
2.1 Abarn
CCESSand
TO Pon all Uother
UBLIC important
TILITIES support functions and structures that are part of 08
............................................................................................................... a
commercial
2.2 DAIRY dairy
FARMunit.
LAY-OUT PRINCIPLES ..................................................................................................... 09
The
2.3 Handbook
DAIRY COWfollows
HOUSE D a ESIGN
modular approach and shows examples of 4 different cow house
................................................................................................................ 10
modules,
2.4 EXAMPLEstarting with OF
LAYOUT 20 Mcows and D
ODULAR moving
AIRY COW to 40,
HOUSE 60 and up to 80 cows. For each module the
...................................................................... 12
design and the layout is illustrated by technical drawings and a description is given
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 about usage
and
2.6 management.
TYPICAL FARM Also a 3DAND
LAYOUT presentation
FENCING is made available. The designs and technical drawings
.............................................................................................. 15
are premised on international best practice dairy management translated to the Kenyan context.
3.2 MANAGEMENT OFFebruary
Nairobi/Leeuwarden, MODULAR 2015FARM DEVELOPMENT PLAN .............................................................. 17
www.snvworld.org
www.thefriesian.nl
www.vetvice.com
3.2.5. Milk Storage ........................................................................................................................... 19
www.modulardairyfarm.com
3.2.9. Water Supply.......................................................................................................................... 21
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester ....................................................................................................................... 35
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CONTENTS
CHAPTER 1: INTRODUCTION
This Handbook presents an investment plan(s) and technical drawings (including a 3D

LIST OF TABLES
presentation .........................................................................................................................................03
in Google SketchUP), for the construction of a modern cow house with utility
buildings. The design and the costings are adjusted to Kenyan conditions, but the principles of the
ABBREVIATIONS .......................................................................................................................................04
design are based on international best practice and standards. The Handbook follows a modular
PREAMBLE
approach and ................................................................................................................................................05
shows 4 stages of development of the dairy farm with modules for 20-40-60-80
lactating
CHAPTER cows plus dry cows and
1: INTRODUCTION young stock for replacement. The target group for this
..............................................................................................................07
Handbook consists of dairy investors, medium and large scale dairy farmers, dairy consultants
and architects.
2.1 ACCESS TO PUBLIC UTILITIES ...............................................................................................................08
2.2 DAIRY
Chapters 1 toFARM LAYHandbook
5 of this -OUT PRINCIPLES contain .....................................................................................................09
explanations and clarifications as regards to the modular
2.3
designDAIRY
and C OW Hdairy
good OUSE D ESIGN ................................................................................................................
management practices. The technical drawings and cost calculations 10
2.4
(BOQs) EXAMPLE LAYOUT
are provided in OF MODULAR
a number DAIRY CAnnexes.
of separate OW HOUSE ...................................................................... 12
2.5 SUPPORT
Although focusFUNCTIONS
is on theAND designPHYSICALand costs STRUCTURES
of the ...........................................................................
cow house itself, the Handbook also pays 13
2.6 TYPICAL
attention FARM L
to support functions
AYOUT AND at theFENCING
dairy farm,..............................................................................................
and the physical structures and systems that need 15
to be put in place to make the dairy farm operational. This includes amongst others reliable access
to electricity and water, land for fodder production, farm mechanisation, buildings and other
3.1 MODULAR
structures FARM of
for storage DEVELOPMENT
feed, fodder ........................................................................................................
and fertilizers, sheds for farm machinery and fencing of the 16
3.2
farm. M ANAGEMENT OF M ODULAR F ARM D EVELOPMENT P LAN .............................................................. 17
3.2.2. Manure Storage/Waste
The modular concept shows two major Waterchallenges
Storage...................................................................................
- at the same time objectives. The first is 18 to
achieve a high level of cow comfort and efficient work processes (e.g. short animal and milk 19
3.2.4.
transportation Treatment/Handling
routes). The secondofisCows.................................................................................................
to design a physical structure (cow house) that can be easily 19
3.2.5. Milk Storage ...........................................................................................................................
expanded at low cost to allow growth of the farm/herd, whilst maintaining the efficiency of the 19
3.2.6.
work processes. Cows: Milk Production and Dimensions ............................................................................... 20
3.2.8. 2Grouping
In Chapters and 3 the of Young
lay out Stock and.......................................................................................................
functions of the modular cow house with utilities are 21
3.2.9. Water Supply..........................................................................................................................
described, and other farm support structures and facilities are mentioned. The stables are designed 21
to accommodate the dairy cattle in-doors in a free walking setting all year round. There is also an
outdoor free walking area and, depending on the farm setting, there is a possibility to include exits
for cattle to enter the grazing fields. In the free walking design concept, animals have access to
3.4 FEED FENCE ........................................................................................................................................... 26
clean drinking water, a central feed alley and cubicles where they can lay down and rest.
3.4.1. Breeding Bull(s)...................................................................................................................... 26
Chapter 4 presents a summary of the investment plan for the modular cow house and the utilities.
3.4.3. Week-planning........................................................................................................................ 28
More detailed cost calculations per module – including Bills of Quantity – are provided in the
Annexes. This chapter also gives a short overview and explanation of other investments that need
to be made on the farm, e.g. in the dairy herd, fodder production, silage pits, hay barn, feed stores
CHAPTER
and in farm4:machinery.
COST CALCULATIONS
These investments FOR areTHE to anMODULAR
important extent BARN DESIGN
elastic and will ..........................
increase with 34
the modular
4.1 COW Hdesign.
OUSE CONSTRUCTION COSTS .................................................................................................. 34
In Chapter
4.1.2. 5, the planning
Biogas process for the implementation of the modular cow house concept 35
Digester....................................................................................................................... is
presented. This is a guideline or checklist for the project owner and his advisors, on how best
4.2 HERD DEVELOPMENT ........................................................................................................................... 35 to
manage
4.3 thePdairy
MILK projectAND
RODUCTION step-by-step.
MILK STORAGE Chapter 5 recommends that the investor engages timely
........................................................................................... 36
with government authorities such as local authorities, and involves a professional architect and
contractor
4.5 MANURE to Passure,
RODUCTION amongst
AND STORAGEothers, ...............................................................................................
compliance with County governments’ land use 39
planning/zoning, attainment of building licenses and permits, an optimal
4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 farm layout
configuration,
4.7 SUMMARYand FARMproper technical
STRUCTURE Mspecifications
EASUREMENTSof materials and prices.
................................................................................. 41
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CONTENTS
CHAPTER 2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS
Before establishing a dairy farm, consideration must be given to all core and support facilities such
LIST
as theOF barn .........................................................................................................................................03
TABLES
cattle or the cow house with the milking parlour and other utilities, feed storage,
manure storage, farm machinery and so on and so forth. Also the demands of a dairy farm
ABBREVIATIONS .......................................................................................................................................04
operation in terms of water and energy use and fodder production and pastures must be well
understood. ................................................................................................................................................05
PREAMBLE
There
CHAPTER is a major difference in factors
1: INTRODUCTION to consider when an existing barn is being expanded or
..............................................................................................................07
modified, or in case a new cow house is to be built from scratch. In this Handbook the
establishment of a new dairy farm operation is described, as this covers the whole range of action
2.1 Ato
points TO PUBLICfor
be considered
CCESS UTILITIES ...............................................................................................................08
best practice cow house design and planning.
2.2 DAIRY Fbelow
The sections ARM Ldescribe
AY-OUT Pthe minimum
RINCIPLES .....................................................................................................09
considerations and principles to be adhered to – from a
2.3
view ofDAIRY COW HOUSE
international bestDpractice.
ESIGN ................................................................................................................
Although the Kenyan situation will differ and every farm and 10
2.4 EXAMPLE
farm site has itsLunique
AYOUT OF MODULAR
features DAIRY
– as will beCthe OWcaseHOUSE for ......................................................................
the investment capacity and vision of the 12
2.5 Sinvestor/entrepreneur
dairy UPPORT FUNCTIONS AND PHYSICAL
– these STRUCTURES
principles are not...........................................................................
compromised in this Handbook to suit the 13
2.6 TYPICAL
“investor” FARM LAYOUT
or “common AND FRather
practice”. ENCINGthese ..............................................................................................
principles give guidelines and benchmarks based 15
on scientific and practical proven concepts for optimization of dairy production and profitability
worldwide. It is up to the reader of this Handbook to pick from them and to see what is attainable
and MODULARatFARM
3.1 achievable DEVELOPMENT
the short and the long ........................................................................................................
run in his or her specific situation. 16
2.1 3.2.2.
Access toManure
PublicStorage/Waste
Utilities Water Storage................................................................................... 18
A commercial
3.2.4. dairy farm needs of
Treatment/Handling good access to roads, electricity and water, for the following
Cows................................................................................................. 19
reasons:
3.2.5. Milk Storage ........................................................................................................................... 19
a. Road3.2.7.network: Good
Special Needsroad Cowsaccess to the farm site is an important issue to consider, as road
................................................................................................................ 21
construction
3.2.8. costs are
Grouping of significant
Young Stockand it is essential for the dispatch of fresh milk and supply 21
....................................................................................................... of
feed. GoodWater
3.2.9. accessSupply..........................................................................................................................
to the main road network and proper logistics on the farm have important 21
impact
3.2.10.on Essential
milk qualityPointsand transportation
to Consider costs. This is important especially for long term
for each Module........................................................................ 22
planning,
3.2.11. so that whentovolumes
Management of feed and
Increase Number milk grow the infrastructure will accommodate
of Cows............................................................................. 22
3.3 theDgrowth.
ESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23
3.4 FEED FENCE ........................................................................................................................................... 26
b. Electricity
3.4.1. supply:
BreedingABull(s)......................................................................................................................
connection to the national grid is preferred as electricity is required on the 26
farm for certain farm operations, such as automated milking, cooling and feed 27
3.4.3. Week-planning........................................................................................................................
milling/chopping. Special attention must be given to a high voltage (3-phase) power 28
3.5 connection,
HYGIENE AND whichBIOSECURITY
may be a ................................................................................................................
requirement for milking and cooling processes. A high voltage 29
3.6 power
TREATMENT AND H
connection is ANDLING
a considerable DAIRY C ATTLE ....................................................................................
investment and will usually increase with the distance 32
between4:the
CHAPTER farm CALCULATIONS
COST site and the nearestFOR high THE voltage power distribution
MODULAR BARN DESIGN point. .......................... 34
4.1 Water
c. HOUSE and
COWsupply CONSTRUCTION
drainage: The COSTS ..................................................................................................
availability of sufficient clean water is important for animals, 34
4.1.1.
farm Construction
processes Costs alike.
and humans Cow House Rain Modules
water catchment1-4 ........................................................................
may help to create (seasonal) storage 34
4.1.2. Biogas Digester.......................................................................................................................
for drinking water for a limited herd size. However for commercial dairy farming a continuous 35
4.2 supply
HERDof DEVELOPMENT ...........................................................................................................................
fresh water must be guaranteed to avoid shortages of drinking water. Besides, clean 35
4.3 water
MILKisPRODUCTION
needed for AND MILKfarm
cleaning STORAGE ...........................................................................................
equipment such as the milking machines and the milk 36
4.4 cooling
FEED AND F EED STORAGE REQUIREMENTS ......................................................................................... 37
tank, but also for cleaning of floors in the milking parlour and milk room. In the event
4.5 that
MANURE
a pipedPRODUCTION AND STORAGE ............................................................................................... 39
water connection to the national grid is not possible or feasible, the installation of
4.6 a deep
OTHER FARM
well BUILDINGS
or borehole AND STORAGES .......................................................................................... 40
needs to be considered. Also the issue of water drainage must be given
4.7 attention.
SUMMARY FARM STRUCTURE
Especially in the event MEASUREMENTS
of heavy rainfall, .................................................................................
excess water must be channelled away from 41
the farm site to existing water reservoirs, drainage canals or the local sewage system.
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CONTENTS
2.2 Dairy Farm Lay-out Principles
The optimal lay-out of a dairy farm takes into account the following principles:
Principles
LIST OF TABLES ......................................................................................................................................... 03
a. One central entry and exit point
ABBREVIATIONS ....................................................................................................................................... 04
b. One central square
PREAMBLE
c. Central view ................................................................................................................................................
on the farm/central square 05
d. Straight 1:
CHAPTER and short lines for all traffic
INTRODUCTION (people and vehicles)
.............................................................................................................. 07
e. The premises are fenced
CHAPTER
f. The route2: to
STRUCTURES,
pasture and arable CONSIDERATIONS
land is separate from AND central entry and.................................
theIMPLICATIONS exit point. 08
Explanations
a.
2.3 One central
DAIRY COW entry
HOUSE andDexit ESIGN point................................................................................................................ 10
2.4 EXAMPLE LAYOUT OF MODULARvehicles
This enables the farm to check DAIRY Cand OW H persons coming in and going out. Facilities for
OUSE ...................................................................... 12
disinfection of vehicles and persons entering the farm can be placed
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 here. One central gate
2.6 allows for strict
TYPICAL FARMcontrol
LAYOUTand AND monitoring of vehicles and persons coming in and going out. The
FENCING .............................................................................................. 15
amount of space needed for drive ways is minimized
b.
3.1 One central square
MODULAR FARM DEVELOPMENT ........................................................................................................ 16
3.2 AllMon-farm
ANAGEMENT trafficOFmovements
MODULAR Fand ARMwork processes Pshould
DEVELOPMENT start from here. The buildings and
LAN .............................................................. 17
the3.2.1.
main working areas are ideally located as close as possible to the central square. Entries
Capacity of the Milking Parlour ............................................................................................. 17 and
exits of all buildings
3.2.2. are situatedWater
Manure Storage/Waste at theStorage
square-side in the most logical place. This lay-out gives
................................................................................... 18
a very
3.2.3.good overview
Waiting Areaover(HoldingmostPen) processes that are happening on the farm and short walking
.................................................................................................. 19
distances.
3.2.4. People are close together
Treatment/Handling of Cows and this supports easy supervision and communication. 19
.................................................................................................
3.2.5. Milk Storage ........................................................................................................................... 19
c. Central
3.2.6. view
Cows: Milk Production and Dimensions ............................................................................... 20
3.2.7. SpecialorNeeds
The farm house Cows ................................................................................................................
the office should be placed in such a way that the farmer or farm manager 21
has3.2.8.
a goodGrouping
view on the of Young
central Stock
gate.......................................................................................................
and the central square. Windows at the place where people 21
3.2.9. Water Supply ..........................................................................................................................
sit (office, kitchen and canteen) should be facing the central gate and the central square. In this 21
manner farm workers can be continuously supervised and visitors are immediately detected. 22
3.2.10. Essential Points to Consider for each Module ........................................................................
3.3 D ESIGN
d. Straight FLOORS
OF short
and AND
lines forCall traffic.....................................................................................................
UBICLES movements: people and vehicles 23
3.4 Cows,
FEEDpeople,
FENCE ...........................................................................................................................................
and moveable machinery should move in straight lines on the farm. This makes 26
3.4.1. Breeding Bull(s) ......................................................................................................................
it easy to drive around with farm machinery (time saving, less accidents) and the space needed 26
for drive and walk ways is minimized. Regarding buildings: designing the farm in straight 27
3.4.3.
lines makesWeek-planning
it easy to expand ........................................................................................................................
buildings. 28
3.6
e. The TREATMENT
premises are AND HANDLING
fenced and can DAIRY CATTLE ....................................................................................
be enclosed with a gate 32
It is advisable
CHAPTER 4: COSTto fence the farm and put
CALCULATIONS FOR oneTHE main entrance, possibly
MODULAR BARN DESIGN with an additional gate 34
.......................... at
the cow house area. This will enhance safety and prevent other animals to enter the farm and
bring in contagious diseases. At the central gate hygienic measures for vehicles and humans
can be executed.
4.1.2. Biogas Digester ....................................................................................................................... 35
f. Separate route to pasture and arable land
The arable land and pastures should be fenced and need to accessible through a separate route
rather than through the main gate. This allows for separation of vehicles and animals from
outside and inside the farm (bio-security, safety).
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CONTENTS
2.3 Dairy Cow House Design
An efficient and effective dairy barn or cow house design is based on the following principles1:
a) Cow comfort
b)
LIST Labour efficiency,
OF TABLES safety and comfort
.........................................................................................................................................03
c) Simple, robust, flexible and expandable
ABBREVIATIONS .......................................................................................................................................04
d) Durable, cheap
PREAMBLE
e) Straight lines................................................................................................................................................05
f) Concentration
CHAPTER of labour
1: INTRODUCTION ..............................................................................................................07
g) Optimizing and separating flows:
CHAPTER
 Cow2:flow STRUCTURES,
(over the day,CONSIDERATIONS
over the year) AND IMPLICATIONS .................................08
2.1  AFeed
CCESSflow
TO PUBLIC UTILITIES ...............................................................................................................08
2.2  DManure
AIRY FARM flow LAY-OUT PRINCIPLES .....................................................................................................09
2.3 DAIRY COW HOUSE Dflow
 People flow/work ESIGN ................................................................................................................ 10
Materials
2.4  EXAMPLE flow OF MODULAR DAIRY COW HOUSE ...................................................................... 12
LAYOUT
Information
2.5  SUPPORT FUNCTIONSflow AND PHYSICAL STRUCTURES ........................................................................... 13
In view of good animal health care practises, the preferred stable is designed in such a way that it
CHAPTER
can 3: CATTLE
accommodate animals BARNof allMODULAR
age groups separately APPROACH in aAND OPERATIONS
free walking area all year ............................
round. 16
At
3.1 theMsame timeFit
ODULAR ARM must facilitate labour
DEVELOPMENT processes – e.g. milking, feeding and manure collection16–
........................................................................................................
in
3.2a safe and efficientOF
MANAGEMENT manner.
MODULAR It also
FARM must provide highPLAN
DEVELOPMENT cow..............................................................
comfort for optimal milk production 17
and good
3.2.1. ventilation and protection against unfavourable weather conditions (e.g.
Capacity of the Milking Parlour............................................................................................. 17 heat, rain,
wind).3.2.2. Manure Storage/Waste Water Storage................................................................................... 18
Free stall
3.2.4.system (cubicle housing)of Cows................................................................................................. 19
Treatment/Handling
There3.2.5.
are different
Milk systems to accommodate dairy cattle, of which free stall, loose housing and the
Storage ........................................................................................................................... 19
tie stall are theCows:
3.2.6. mostMilk common ones. and
Production In this Handbook
Dimensions the free stall system is selected as the most
............................................................................... 20
3.2.7. Special Needs Cows ................................................................................................................
appropriate design for the Kenyan situation. The free stall gives a higher level of cow comfort. 21
Cows 3.2.8.
are cleanerGrouping
and there of Young Stock .......................................................................................................
is a lower incidence of teat/udder injury. Compared to loose housing 21
3.2.9. Water Supply..........................................................................................................................
the investment is comparable or slightly lower, due to the facts that in the same surface in a free 21
3.2.10. Essential Points to Consider for each Module........................................................................
stall barn a higher number of animals can be kept, but construction costs per square meter are 22
higher.3.2.11. Management
Loose housing alsotorequires
Increase more Number useofof Cows.............................................................................
bedding material and labour to handle manure. 22
3.3 D ESIGN OF F LOORS AND C UBICLES .....................................................................................................
The tie stall design provides the least cow comfort of the 3 systems because animals are restrained 23
3.4 FEED Fexercise
and cannot ENCE ...........................................................................................................................................
at will. 26
3.4.1. Breeding Bull(s)...................................................................................................................... 26
3.4.2.mostSchedule
The three commonfor Barncow
dairy Inspection
house Rounds
types: .................................................................................... 27
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester....................................................................................................................... 35
Freestalls Loose housing Tiestalls
1 From: Building for the cow. Jan Hulsen. Roodbont Publishers; 2008. Page 1
Page 10
page | 10
CONTENTS
In this modular free stall design, cattle can use a (fenced) free walking area (dry lot) outside the
barn structure. This area can be closed in periods with much rainfall. And it can be taken out the
design i.e. when cows have access to pasture. Access to pasture is anticipated for in the design.
LIST important.........................................................................................................................................
OF TABLES
The most parameters for the design of the cattle barn are as follows: 03
ABBREVIATIONS ....................................................................................................................................... 04
a. Cows in lactation
PREAMBLE
b. Dry cows (Far ................................................................................................................................................
off/Close up) 05
c. Maternity
CHAPTER 1: (calving
INTRODUCTION area) .............................................................................................................. 07
d. Calf rearing (age 0 – 3 months) in calf boxes and group housing *
CHAPTER
e. 2: STRUCTURES,
Female young stock (age 4 -7 CONSIDERATIONS
months) AND IMPLICATIONS ................................. 08
f.
2.1 Female young
ACCESS stock (age
TO PUBLIC UTILITIES8 – 11...............................................................................................................
months) 08
g.
2.2 Heifers
DAIRY(age
FARM 12L–AY 15-OUT
months)PRINCIPLES ..................................................................................................... 09
h.
2.3 Pregnant
DAIRY Cheifers
OW HOUSE (age D 16ESIGN
– 19 months)
................................................................................................................ 10
i.
2.4 Pregnant
EXAMPLEheifers
LAYOUT (ageOF20MmonthsODULAR– D delivery)
AIRY COW HOUSE ...................................................................... 12
j.2.5 Breeding bull(s) *
SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13
(* Note: In this Handbook it is assumed that bull calves are not kept for rearing and leave the farm within two weeks after calving.
CHAPTER
However, 1 or 23: CATTLE
bulls BARN
may be selected MODULAR
for the APPROACH
purpose of breeding AND
(natural mating) OPERATIONS
for cows ............................
that are difficult to conceive through AI. 16
In
3.2 addition to the OF
MANAGEMENT listMabove, the following functions in the cow house design also need
ODULAR FARM DEVELOPMENT PLAN .............................................................. 17
consideration:
a. Cow handling
3.2.3. Waiting andArea treatment
(Holding areaPen) .................................................................................................. 19
This area
3.2.4. is
Treatment/Handling of Cowsto.................................................................................................
usually closely located the milking parlour. It is used to single-out cows from 19
the herd
3.2.5. for purposes of individual attention, for example hoof-trimming, artificial
Milk Storage ........................................................................................................................... 19
insemination
3.2.6. Cows: or Milk
veterinary
Production treatments. In this area,
and Dimensions an individual treatment box can be located
............................................................................... 20
in3.2.7.
which individual
Special Needs animals can be confined for treatment. At farms that have a dairy herd 21
Cows ................................................................................................................ of
more than
3.2.8. 60 cows a separate “attention area” is recommended, where animals are
Grouping of Young Stock ....................................................................................................... 21 housed
temporarily
3.2.9. during
Water Supply a ..........................................................................................................................
period of time outside their normally allocated barn space, for the 21
purpose
3.2.10. ofEssential
individual Points monitoring
to Considerorfortreatment each Module (e.g. animals with lameness, mastitis or any
........................................................................ 22
other conditions
3.2.11. Management that would call for
to Increase regular
Number attention).
of Cows ............................................................................. 22
b.
3.4 Milking parlour
FEED FENCE ........................................................................................................................................... 26
A3.4.1.
milkingBreeding
parlour is the location
Bull(s) at the farm where cows are generally milked twice a day. The
...................................................................................................................... 26
reason
3.4.2. to milk
Schedulecows foratBarn
the same
InspectionlocationRounds is because this place can be equipped with stationary
.................................................................................... 27
milking
3.4.3. machinery
Week-planning and........................................................................................................................
a safe and hygienic working environment can be created with 28
3.5 HYGIENElight
sufficient ANDand BIOSECURITY
ventilation. ................................................................................................................
From an ergonomics point of view a milking parlour provides 29
3.6 a Tgood position
REATMENT AND forHmilkers
ANDLING to D work CATTLE
AIRYsafely and ....................................................................................
keep a good view at udder level. 32
c. Milk- and machine room
4.1 This
COW isHaOUSE CONSTRUCTION
dedicated area for the COSTS ..................................................................................................
reception, cooling and the storage of milk. This is the place 34
4.1.1. the Construction
where Costs milk
dispatch of fresh Cow House Modules
takes place. 1-4also
It is ........................................................................
used to manage the cleaning of milking 34
4.1.2. Biogas Digester .......................................................................................................................
equipment, utensils and milk cans. Where applicable this is also the place where the milk 35
4.2 testing
HERD equipment
DEVELOPMENT ...........................................................................................................................
is stored. Situated adjacent to the milk room is the machine or equipment 35
4.3 room
MILKinPRODUCTION AND MILK
which compressors and STORAGE
vacuum...........................................................................................
equipment are placed. The heat radiating equipment 36
4.4 isFphysically
EED AND FEED STORAGE R EQUIREMENTS .........................................................................................
separated from the cooling equipment. The cooling equipment is instead located 37
4.5 inMthe
ANURE PRODUCTION
milk-room to avoid STORAGE ...............................................................................................
ANDinconsistent flows of (heated) air and contamination by oils and 39
4.6 lubricants.
OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40
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CONTENTS
d. Office and sanitation room
An office is an absolute necessity for proper management and administration. Some of the
management aspects include farm recording, herd fertility and AI, animal health and
veterinary care. Also the (cold) storage of veterinary medicines, artificial insemination utilities
LIST(including
OF TABLES bull.........................................................................................................................................03
semen) and spare parts of the milking equipment are kept in the office room. It
is recommended that a sanitation unit be included in close vicinity of the office which houses
ABBREVIATIONS .......................................................................................................................................04
the toilet with the washing area and the changing room.
PREAMBLE ................................................................................................................................................05
2.4 Example Layout of Modular Dairy Cow House
Figures 1 and 2 show the basic layout of the modular cow house design as explained in this
Handbook. The example below is for the 40 cow module 2 cow house unit. The principles of this
2.2 DAIRY FARM LAY-OUT PRINCIPLES .....................................................................................................09
unit are the same for the other modules (1: 20 cows; 3: 60 cows and 4: 80 cows). Detailed technical
drawings of all modules are provided in the Annexes. See also Figure 15.
It should be noted that the reference to 20-40-60-80 cows as per the module titles, is based and
determined by the number of lactating cows in each module. Thus in module 2: “40 cows” barn,
CHAPTER
means 3: CATTLE
40 lactating cows,BARN
and soMODULAR
on for the other APPROACH
modules. AND OPERATIONS
This implies however ............................
that the total herd 16
per
3.1 module
MODULARis larger
FARM asDitEVELOPMENT
includes also dry cows and young stock (the latter for replacement). This
........................................................................................................ 16
applies to all modules.
Equally and inManure
3.2.2. line with this, the housing
Storage/Waste Watercapacity for each module is determined by the total herd,
Storage................................................................................... 18
which3.2.3.
includesWaiting
cows inArea lactation, dry cows and young stock. For illustration purposes reference19
(Holding Pen) .................................................................................................. is
made 3.2.4.
to Table Treatment/Handling
11 in Chapter 4, which gives a breakdown of the total herd for the 4 modules (for192
of Cows.................................................................................................
scenarios).
3.2.5. All four cow house modules in this Handbook are designed to accommodate this total
Milk Storage ........................................................................................................................... 19
herd. 3.2.6. Cows: Milk Production and Dimensions ............................................................................... 20
Thus the design
3.2.8. in figure
Grouping of 2Young
belowStock encompasses both the accommodation for cows in lactation (40),
....................................................................................................... 21
dry cows
3.2.9.and Water
youngSupply..........................................................................................................................
stock. The lactating cows are housed in a free stall system. Young stock and 21
dry cows are housed
3.2.10. EssentialinPointsa loose housing for
to Consider system (in group boxes), which are located opposite the
each Module........................................................................ 22
lactating cows.Management
3.2.11. The required materials
to Increase Number- including an estimated cost - are shown in the Bill 22
of Cows............................................................................. of
Quantities
3.3 DESIGN in Annex
OF FLOORS 4 (BOQ)AND C and summarized
UBICLES in Chapter 4. The BOQ makes a distinction between
..................................................................................................... 23
an option
3.4 FEEDthat uses
FENCE wooden frames and an option that applies steel beams.
........................................................................................................................................... 26
3.4.1. Breeding Bull(s)...................................................................................................................... 26
Figure3.4.2.
1. BarnSchedule
designfor (side
Barn view)
Inspection Rounds .................................................................................... 27
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester....................................................................................................................... 35
For more details see technical drawing: Annex – 3.f TD 20 cows module
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CONTENTS
Figure 2. Barn layout (top view 40 cows module)
LIST OF TABLES ......................................................................................................................................... 03

ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.6. Cows: Milk Production and Dimensions For more details see technical drawing: Annex – 3.e TD Farm layout
............................................................................... 20
2.5 Support Functions and Physical Structures
3.2.9. Water Supply.......................................................................................................................... 21
Next to the cow house and utility buildings, the dairy farm has a number of other buildings and
structures of which the most common are:
3.4 FEED FENCE ........................................................................................................................................... 26
a. Feed storage/handling area: sufficient space must be allocated for structures to store dairy feed
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
such as:
 Hay and straw, located near the cattle barns in an open structure that could have the roof
3.4.3. Week-planning........................................................................................................................ 28
only.
3.6  TSilage bunker silo (maize, grass, sorghum, etc.) located in close vicinity to the cattle barns,
REATMENT AND HANDLING DAIRY CATTLE .................................................................................... 32
preferably made of reinforced concrete to allow access of tractors and heavy loads during
CHAPTER 4: COST
the silage makingCALCULATIONS
operations. FOR THE MODULAR BARN DESIGN .......................... 34
4.1  CDairy
OW HOUSEfeed concentrates
CONSTRUCTION (mixed
COSTSand as raw materials) are preferably stored in a separate
.................................................................................................. 34
building.
4.1.1. Milling and mixing of concentrate rations takes place at this location.
Construction Costs Cow House Modules 1-4 ........................................................................ 34
4.1.2. Biogas Digester ....................................................................................................................... 35
4.2 In selecting the best location
HERD DEVELOPMENT on the farm for these feed storage structures, due attention must be
........................................................................................................................... 35
given to easy access of farm machinery – e.g. tractors, maize harvesters, feed
4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36trailers - and to
4.4 prevent interference
FEED AND with waste
FEED STORAGE or manure .........................................................................................
REQUIREMENTS storages/processing lines. 37
b. Cattle
4.6 dip/spray
OTHER area: Frequent
FARM BUILDINGS AND Sspraying
TORAGES (or dipping) of all cattle is necessary to protect them
.......................................................................................... 40
4.7 against
SUMMARYexternal parasites
FARM STRUCTURE and M tick borne diseases,
EASUREMENTS when they have access to pasture. A spray
................................................................................. 41
race or dipping pit can be located in the vicinity of the cattle barns and can be reached
preferably through a fenced gateway.
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CONTENTS
c. Agriculture utility or inputs store: This building is required to store agriculture tools, fertilizers,
seeds, herbicides and pesticides. It is recommended that this building is lockable. Chemicals
must be stored in a separate cupboard for safety reasons.
LIST OF TABLES .........................................................................................................................................03
d. Farm machinery.......................................................................................................................................04
ABBREVIATIONS storage or go-down: This building protects major farm machinery and
implements against unfavourable weather conditions. It is designed with an open front to allow
PREAMBLE
easy access for ................................................................................................................................................05
large machinery such as a tractor, plough, sowing machine, maize harvester and
chopper and
CHAPTER 1: INTRODUCTIONso on and so forth. The building may also include a small workshop to allow for
..............................................................................................................07
minor repairs, such as tyre repairs, lubrication and servicing of machinery. Spare parts of farm
CHAPTER
equipment 2: can
STRUCTURES,
be stored here. CONSIDERATIONS AND IMPLICATIONS .................................08
e. Drinking
2.2 DAIRY Fwater
ARM Lstorage
AY-OUT P tanks:
RINCIPLES A guaranteed supply of good quality water is important to
.....................................................................................................09
2.3 provide
DAIRYcattle
COW with HOUSE their
DESIGNdaily................................................................................................................
water requirement and for cleaning. Rain water catchment may 10
2.4 be E
used
XAMPLEto provide
LAYOUTpart OF M ofODULAR
this, but will C
DAIRY notOWbe sufficient
HOUSE to guarantee sufficient volumes year
...................................................................... 12
round. It is advised that the farm be connected to the national piped
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 water supply system, or
2.6 sinks a deep-well
TYPICAL FARM L orAYOUT
borehole. AND FENCING .............................................................................................. 15
Water storage tanks with sufficient storage capacity need to be present in the event that the
water supply gets temporally disrupted. As a rule of thumb the water storage capacity should
3.1be M equal
ODULAR to aFARM minimum DEVELOPMENTof two-day ........................................................................................................
water requirement of the cows plus water needed for 16
3.2 cleaning.
MANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
3.2.2. supply
f. Electricity Manureand Storage/Waste
power back-up Waterunit: Storage...................................................................................
Where an electrical power generator is installed on 18
the farm premises, it is recommended that the generator be placed in a separate building away 19
3.2.4.
from the main Treatment/Handling
farm buildings. of Cows.................................................................................................
Safety considerations (particularly in relation to fire protection) 19
3.2.5. Milk Storage ...........................................................................................................................
must be borne in mind when assigning the location of fuel supply and storage facilities. In case 19
3.2.6. Cows: Milk Production and Dimensions ...............................................................................
fuel (e.g. diesel) is stored in an external storage tank, it is recommended that the storage tank be 20
located outside the power back-up building for safety reasons. At the same time this storage 21
3.2.8.
tank may beGrouping
used to of Young
store fuelStock .......................................................................................................
for the farm machinery as well (tractors). The fuel tank needs21 a
concrete slab that will hold any leakages or spoilage from the tank to prevent contamination 21
3.2.9. Water Supply.......................................................................................................................... of
the3.2.10.
soil. Essential Points to Consider for each Module........................................................................ 22
3.3 D
g. ManureESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23
collection and storage bunker/pit: The handling of cow manure is a very important
3.4 operation
FEED FENCE ...........................................................................................................................................
of a dairy farm and requires much attention. Manure must be collected daily and put 26
3.4.1. Breeding Bull(s)...................................................................................................................... 26
in a concrete storage facility or bunker whose design depends on the volume, usage and
destination of the manure. The most common ways of using manure in rural Kenya are:
3.4.3. Week-planning........................................................................................................................ 28
 Organic fertiliser: Manure is stored over a longer period of time in a concrete pit or bunker,
from where it is distributed periodically to agricultural land as an organic fertiliser. This is
CHAPTER 4: COST CALCULATIONS
the recommended practice for integrated FOR THE dairy MODULAR
farms withBARN sufficient DESIGNland to..........................
grow their own 34
4.1 Cfodder. Use is best made of a manure spreader. The frequency of manuring the land
OW HOUSE CONSTRUCTION COSTS .................................................................................................. 34
depends
4.1.1. on the soilCosts
Construction fertility,
Cow demand
House Modules per crop and availability of land. The duration 34
1-4 ........................................................................ of
croppingBiogas
4.1.2. season and rainfall patterns also determine how much manure needs to be stored
Digester....................................................................................................................... 35
over a certain period of time. In Kenyan this period would be between 3 and 6 months.
4.4  FBio-gas:
EED ANDLivestock manure
FEED STORAGE and other organic
REQUIREMENTS waste from the farm (e.g. maize stovers) 37
......................................................................................... is
4.5 Mideal feedstock
ANURE for methane
PRODUCTION gas production
AND STORAGE in so-called biogas digesters. In Kenya there are
............................................................................................... 39
4.6 several low-cost solutions in the market for such “farm-based” bio digesters ranging
OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 from
4.7 SKES 50,000
UMMARY to 150,000,
FARM STRUCTURE depending on size.................................................................................
MEASUREMENTS and materials used. The use of these biogas 41
digesters is widespread in dairy farming systems across the country and the size ranges
from 6-20 m3. The biogas is used for domestic and farm purposes, such as lighting, cooking
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CONTENTS
and heating water for cleaning of the milk tank and the milking machine. It can also be used
to generate electricity, although this requires a considerable extra investment. The slurry
that is accumulated in the biogas digester can be used as an organic fertilizer for soil
improvement and enrichment.
LIST OF different.........................................................................................................................................03
TheTABLES options and requirements concerning biogas digesters and their use are briefly
mentioned in Annex 3. For construction of the biogas digester it is recommended that the
ABBREVIATIONS .......................................................................................................................................04
farmer contacts a certified biogas contractor (http://africabiogas.org/).
PREAMBLE ................................................................................................................................................05
2.6 Typical Farm Layout and Fencing
Figure 3 shows a typical farm lay out with one central entrance gate, the central square in the
middle and the cow house with utility building on the right. (Modular) expansion of the cow
house is preferably in this direction. On the left there is space for other structures including silage
pits and a hay stack. The detailed technical drawing of Figure 3 is presented in Annex – 3.e
TD Farm layout.
It is advised to fence the farm for security and bio safety. Fencing is recommended to avoid
CHAPTER of
movement 3: cattle
CATTLE fromBARN MODULAR
neighbouring areas APPROACH
into the farm AND andOPERATIONS
entering of wild ............................
animals. These 16
movements
3.1 MODULAR mayFspread contagious cattle diseases. Prevention of theft is another reason for fencing
ARM DEVELOPMENT ........................................................................................................ 16
3.2 MANAGEMENT OF MODULARsecurity
the farm and applying additional FARM Dmeasures.
EVELOPMENT PLAN .............................................................. 17
Figure3.2.2.
3. General farm
Manure layout
Storage/Waste Water Storage................................................................................... 18
3.2.4. Treatment/Handling of Cows................................................................................................. 19
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.9. Water Supply.......................................................................................................................... 21
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s)...................................................................................................................... 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester....................................................................................................................... 35
4.2 HERD DEVELOPMENT ...........................................................................................................................
Reference Annex – 3.e TD Farm layout 35
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CONTENTS
CHAPTER 3: CATTLE BARN MODULAR APPROACH AND OPERATIONS
The basic principles concerning the lay-out and design of the cow house and the support functions
LIST OF TABLES
have been .........................................................................................................................................
summarized in the previous chapter, i.e. cow comfort, labour efficiency, robust, durable, 03
straight lines, separation
ABBREVIATIONS of flows.
....................................................................................................................................... 04
This Chapter pays attention to topics that need special attention and care when moving the dairy
farm through a................................................................................................................................................
PREAMBLE “modular” design to the next level, thereby increasing the herd size. It therefore 05
looks more at
CHAPTER 1: management
INTRODUCTION of the dairy herd and the functions as per the modular design.
.............................................................................................................. 07
3.1 Modular
2.1 A CCESS TOFarm Development
PUBLIC UTILITIES ............................................................................................................... 08
Dairy Dfarms
2.3 develop over time by increasing the number of cows. If properly planned and
AIRY COW HOUSE DESIGN ................................................................................................................ 10
implemented,
2.4 EXAMPLEthis expansion
LAYOUT can bring down the costs per kilo of milk produced at the farm, thus
OF MODULAR DAIRY COW HOUSE ...................................................................... 12
maintaining a profitable situation
2.5 SUPPORT FUNCTIONS AND PHYSICAL and allowing
STRUCTURES for the benefits of economies of scale. This is 13
........................................................................... of
particular
2.6 importance
TYPICAL FARM LAYOUTwhen AND
the cost price..............................................................................................
FENCING of milk increases more rapidly than the sales price. 15
Scaling up the dairy herd size and specialisation of farm operations, offer the potential to realize
CHAPTER
economies of 3: scales
CATTLEand BARN MODULAR
cost price reduction per APPROACH
unit (cow,AND litre of milk), thereby ............................
OPERATIONS increasing profits. 16
It
3.1alsoMusually
ODULAR leads
FARM to D
improved quality
EVELOPMENT of raw milk.
........................................................................................................ 16
A well-planned
3.2.1. cattle ofbarn
Capacity and dairy
the Milking Parlour farm are designed in such way that future expansion
............................................................................................. 17
becomes easy
3.2.2. and cost-effective. Dairy farm growth, in terms of expanding farm structures and
Manure Storage/Waste Water Storage................................................................................... 18
facilities, is usually
3.2.3. planned
Waiting in steps Pen)
Area (Holding to accommodate the growth of the herd over time.
.................................................................................................. 19
Designing
3.2.4. a dairy barn and dairy farm is however always a tailor-made process.
Treatment/Handling of Cows ................................................................................................. 19 Very few
investors/dairy
3.2.5. farmers
Milk Storage have the same vision and/or options for developing their dairy farm and
........................................................................................................................... 19
some 3.2.6.
of the parameters
Cows: Milk that vary case
Production andbyDimensions
case include: ............................................................................... 20
a) The amount
3.2.8. of investment
Grouping of Young capital
Stockavailable
....................................................................................................... 21
Little investment
3.2.9. capital..........................................................................................................................
Water Supply is often a reason for investors to decide to use cheap(er) materials and 21
very simple type of construction methods. As a result of this, a cow barn is created that will
wear out faster
3.2.11. and is often
Management more Number
to Increase labour intensive and less comfortable to work in. It may also
of Cows............................................................................. 22
3.3 compromise
DESIGN OF Fon cowAND
LOORS comfortCUBICLESwhich .....................................................................................................
will negatively affect milk production and profitability. 23
3.4 During
FEED FtheENCE ...........................................................................................................................................
upgrading/expansion of the dairy unit, the (sub-standard) buildings that are 26 in
place may need
3.4.1. to be
Breeding fully......................................................................................................................
Bull(s) replaced with new ones, that suit the demands of managing a larger 26
3.4.2.herd.Schedule
dairy for Barn Inspection
“Full replacement Rounds ....................................................................................
of buildings” increases the costs of expanding a dairy farm 27
3.4.3.
considerably. Week-planning
Some examples ........................................................................................................................
of areas of basic decision-making between cheaper and more 28
3.5 durable
HYGIENE AND BIOSECURITY
solutions include: ................................................................................................................ 29
3.6  TREATMENT
To opt for aAND HANDLING DAIRY
milking-parlour with C ATTLEversus
stands ....................................................................................
an integrated milk-parlour with a pit. 32
 Using
CHAPTER wooden
4: COST fences and otherFOR
CALCULATIONS low-cost
THE MODULAR constructionBARN materials DESIGN versus more durable
.......................... 34
materials such as galvanized steel and concrete.
4.1  CEconomize on the size of the cubicles and the height of the cow house at the cost of cow
comfort and ventilation.
4.1.2. Biogas Digester ....................................................................................................................... 35
b) The size and properties of the area on which the buildings are constructed
The site characteristics, e.g. slopes, size, existing buildings, access to water etc., will to a large
extent determine the farm and the barn design. It may lead to decisions that compromise the
basic principles described in this Handbook, for example the principle of straight lines, one
entrance/exit, and even own fodder production versus purchase from outside.
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CONTENTS
c) The farmer’s vision on use of labour versus mechanisation
If labour is cheap and abundant it is tempting to opt for (unskilled) labour-intensive solutions
rather than mechanisation. This however may compromise basic principles of good dairy
husbandry, cow house design and fodder production. In the modular cow house design
LIST OF TABLES
labour efficiency .........................................................................................................................................
is an important factor. This is e.g. visible in the design of the milking parlour. 03
A high capacity .......................................................................................................................................
ABBREVIATIONS of the milk parlour (higher number of milk clusters) reduces the milking time. 04
As a rule of thumb, the number of cows milked per hour is equal to half the number of clusters.
When milk ................................................................................................................................................
PREAMBLE production increases, milking time also increases. 05
d) The time frame for development of the dairy farm
CHAPTER
Investments2: STRUCTURES,
that are not CONSIDERATIONS
yet fully utilized – e.g. ANDovercapacity
IMPLICATIONS of the.................................
milking parlour 08–
2.1 contribute
ACCESS TO toPUBLIC
higherUfixed TILITIES or...............................................................................................................
overhead costs. However, with a short time frame between 08
2.2 development
DAIRY FARM steps LAY-OUT andPRINCIPLES
a well-planned growth strategy based on a modular approach,
..................................................................................................... 09
2.3 “overdesign”
DAIRY COW at the start
HOUSE DESIGN (module one) will reduce total investment costs at later stages in the
................................................................................................................ 10
2.4 growth
EXAMPLE model. In the
LAYOUT OFabsence
MODULAR of D a AIRY
modular COW approach, every expansion of the farm will be12
HOUSE ...................................................................... a
project on its own with the risk of duplication or replacement of existing
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 structures.
e) Market access of farm products
Efficient management of sales and purchases of farm products (milk, breeding stock) and farm
3.1 inputs
MODULAR FARM DEVELOPMENT
(e.g. fertilizers, feed) respectively, ........................................................................................................
may reduce the need for storage facilities. 16
3.2 3.2.2.
Management Manure of Storage/Waste
Modular Farm Development
Water Plan
Storage................................................................................... 18
The development
3.2.4. strategy for theofdairy
Treatment/Handling Cowsfarm – also in a modular design or approach – is partly
................................................................................................. 19
based3.2.5.
on the personal choices and preferences of the investor or farmer, his ability to invest as well
Milk Storage ........................................................................................................................... 19
as the3.2.6.
specificCows:
conditions and circumstances
Milk Production and Dimensions on-site. This has been briefly referred to in the
............................................................................... 20
previous section.
As a general
3.2.8. guideline,
Grouping ofthe Youngfollowing elements of cow house design are however important 21
Stock ....................................................................................................... to
consider timelyWater
3.2.9. and Supply
adequately across the board, to allow for easy expansion and effective use 21
.......................................................................................................................... of
resources. For example
3.2.10. when moving
Essential Points to Consider from for20-80 cows (plus
each Module young stock) in a stepwise manner: 22
........................................................................
a. Capacity
3.3 DESIGNof OFthe milking
FLOORS AND parlour
CUBICLES ..................................................................................................... 23
b.
3.4 Manure
FEED Fstorage/waste water storage
ENCE ........................................................................................................................................... 26
c. Waiting
3.4.1. area beforeBull(s)
Breeding milking ...................................................................................................................... 26
d. Treatment
3.4.2. and handling
Schedule for Barn of cows
e. Milk storage
3.4.3. Week-planning........................................................................................................................ 28
3.5 Cows:
f. HYGIENE
milk AND BIOSECURITY
production ................................................................................................................ 29
and dimensions
3.6 T
g. Special needs cows
REATMENT AND H ANDLING DAIRY CATTLE .................................................................................... 32
h. Grouping
CHAPTER 4: of young
COST stock
CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
3.2.1. 4.1.1.
Capacity of the Milking
Construction Costs Cow Parlour
House Modules 1-4 ........................................................................ 34
4.1.2. Biogas Digester ....................................................................................................................... 35
The
4.2 design
HERD of the required...........................................................................................................................
DEVELOPMENT milking parlour capacity is based on the assumption that total milking 35
time (milking + cleaning of the milking parlour, milking equipment and holding pen)
4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 should not
take
4.4 more
FEED time
AND Fthan
EED Stwo hours,
TORAGE and the last .........................................................................................
REQUIREMENTS cow that is milked should not have been standing 37
waiting
4.5 MANURElonger Pthan 60 minutes
RODUCTION AND S (2x per day
TORAGE milking), or 45 minutes (3x per day milking). It 39
............................................................................................... is
furthermore assumed that the first cows immediately enter the parlour and the last
4.6 OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40cow enters the
parlour exactly 60
4.7 SUMMARY minutes
FARM later, atMthe
STRUCTURE latest.
EASUREMENTS ................................................................................. 41
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CONTENTS
During the modular stages 3 and 4 (60 and 80 cows), the dairy herd can be separated into two
groups. In this situation only half the milk parlour capacity is needed.
In the modular stages 1 and 2 (20 and 40 cows), the cows have to wait between the stalls and the
outside wall of the barn, before they can be milked. In this situation, some of the cows can lay
LIST OF
down TABLES
while .........................................................................................................................................03
waiting. This slightly reduces the need for milking all cows within one hour and
fifteen minutes as long as the stalls are available for the cows that are waiting.
ABBREVIATIONS .......................................................................................................................................04
PREAMBLE
Table 1. Number ................................................................................................................................................05
of clusters needed to milk all cows in 1 hour and 15 minutes:
CHAPTER 1: INTRODUCTION Average milk..............................................................................................................07
production/day
Dairy herd: 15-20 Lt 20-30 Lt
CHAPTER
20 cows 2: STRUCTURES, 3 clusters CONSIDERATIONS AND 4IMPLICATIONS clusters .................................08
40 cows
2.1 ACCESS TO PUBLIC 3 swing
UTILITIES over,...............................................................................................................08
or 6 (2 x 3) 8 (2 x 4)
2.2 DAIRY FARM LAY
60 cows 5 -swing
OUT PRINCIPLES
over, or 10.....................................................................................................09
(2 x 5) 12 (2 x 6)
2.3 DAIRY COW HOUSE
80 cows 6 swingDESIGN over, ................................................................................................................
or 12 (2 x 6) 16 (2 x 8) 10
2.5 S1UPPORT
Table FUNCTIONS
above shows the growthAND Psteps HYSICAL STRUCTURES
of the milk parlour. ...........................................................................
The farmer can start milking on one side 13
2.6theTparlour
of YPICAL FinARM LAYOUT
modular AND1:FENCING
stage 20 cows...............................................................................................
And then switch to milking on two sides in modular 15
stage
CHAPTER2: 40 cows. In a herd
3: CATTLE BARNwith MODULAR
a milk production APPROACH of up to AND 20 litres per day per cow
OPERATIONS (+/-), a swing-
............................ 16
over system can be used with limited disadvantages. In a swing over system, a cluster hanging in
3.1 centre
the MODULARof the FARMparlourDEVELOPMENT
is used for ........................................................................................................
milking the cows on both sides. As cows with higher 16
3.2 M ANAGEMENT OF M ODULAR F ARM D EVELOPMENT
production need more time to be milked out, in herds with higher productions a swing over P LAN .............................................................. 17
system 3.2.1. Capacity
is far less optimal of the Milking
as cows haveParlour.............................................................................................
to wait long before the cluster can be attached. 17
3.2.2. 3.2.4.
Manure Storage/Waste Water
Treatment/Handling Storage
of Cows................................................................................................. 19
3.2.5. Milk Storage ........................................................................................................................... 19
Until 3.2.6.
the outsideCows: waiting area is constructed
Milk Production and Dimensions (module 3: 60 cows), the manure is collected in an
............................................................................... 20
open storage basin. Manure is collected by scraping it off the floor manually. The outside waiting
area can be constructed
3.2.8. Grouping ofon Youngtop Stock
of the open manure storage, by building two small walls and
....................................................................................................... 21
making a concrete
3.2.9. Waterfloor on top. The manure storage can also be used as waste water storage. An
Supply.......................................................................................................................... 21
3.2.10. Essential Points to Consider for each Module........................................................................
overflow construction must be put into place, enabling the waste water to flow to a designated 22
place 3.2.11.
in case theManagement
manure storage to Increasebasin Number
or pit of isCows.............................................................................
full. From this moment on, the manure is scraped 22
3.3 D F C .....................................................................................................
and directed into a channel and flows by gravitation into the newly constructed manure storage,
ESIGN OF LOORS AND UBICLES 23
3.4
next toFEED FENCE ...........................................................................................................................................
the holding pen. 26
3.4.1. Breeding Bull(s)...................................................................................................................... 26
Example of poor manure handling: do not 27
3.4.3. Week-planning........................................................................................................................
let manure run off. Manure is a valuable 28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................
fertilizer for both food and fodder crops. 29
3.6 TREATMENT AND HANDLING DAIRY CATTLE ....................................................................................
Proper storage and application on the 32
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR cropping
BARN area is crucial........................... 34
DESIGN
4.1.2. Biogas Digester....................................................................................................................... 35
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CONTENTS
3.2.3. Waiting Area (Holding Pen)
In the 20 and 40 cows modules (1 and 2), the alley between the stalls and the outside wall is used
as the waiting area. After milking, the cows move into the alley between the stalls and the feed
fence.
LIST OFAt this moment
TABLES the feed trough must be filled.
......................................................................................................................................... 03
When dealing with more than 60 cows, there is need to construct an outside waiting area or
ABBREVIATIONS ....................................................................................................................................... 04
holding pen. The cows must enter this area at the far end of the cow house, away from the milking
PREAMBLE
parlour and most................................................................................................................................................
certainly not at the front close to the parlour. A separate alley to this waiting area 05
can be created,
CHAPTER enabling the herd to
1: INTRODUCTION be milked in two groups. In this approach, each group changes
.............................................................................................................. 07
pen with each milking.
3.2.4. Treatment/Handling of Cows
2.3small
In DAIRY COW
herds of H to 40Dcows,
upOUSE ESIGN ................................................................................................................ 10
animal handling for health checks, treatments and inseminations
are mostly done on individual cows one at a time. Therefore, these treatments can be done with the
2.5 standing
cow SUPPORTin
FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13
a stall or in another place where she can be tied up. Cows in small herds usually
are easy to catch and position. In bigger herds, animal handling, checks and treatments are more
often
CHAPTERdone in3: groups,
CATTLE with
BARN moreMODULARcows at a time. Spotting, AND
APPROACH catching and positioning
OPERATIONS a cow requires
............................ 16
more time. This makes a self-locking feed fence a good place to organize and create a facility for
cow inspections and treatments and to safe time catching cows.
In the design, a self-locking feed fence is installed when the dairy farm reaches the 3rd modular
stage (60 cows). The farmer may also decide to install it in an earlier stage of course.
3.2.5. 3.2.4.
Milk Treatment/Handling
Storage of Cows ................................................................................................. 19
3.2.5. Milk Storage ........................................................................................................................... 19
When3.2.6. Cows: Milk
milk volumes grow Production
to volumes and of Dimensions
500-1,000...............................................................................
litres per day and above, an investment in20a
milk chilling tank is a logical and necessary step. This also may depend on the logistical 21
3.2.8.
arrangements Grouping
in place of
asYoung
regards Stock to.......................................................................................................
milk collection and sales. Some farmers may be able 21 to
transport and sell their raw milk immediately after each milking, or store the milk for half a day 21
3.2.9. Water Supply .......................................................................................................................... in
milk-cans. The latter is only acceptable if the milk can be kept in a cooled/chilled environment.
However with higher volumes being produced and stored at the farm – at some point - a chilled
milk tank becomes a requirement for proper raw milk handling and storage, in order to assure
3.4 FEED FENCE ........................................................................................................................................... 26
micro biological quality.
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
Milk cooling tanks can vary in size from 500 – 10,000 litres. The advantage of the smallest size
cooling tanks is that they can operate on a 2-phase electricity system. The larger sizes need 3-
3.4.3. Week-planning........................................................................................................................ 28
phase, however solutions can be found by fitting 2 compressors on 2-phase rather than one big
compressor on 3-phase. A milk tank requires sufficient amount of space. Table 2 shows the
estimated milk production in two (2) days for the 4 modules, thus showing the minimal storage
CHAPTER 4: COST
capacity required whenCALCULATIONS
the milk is collected FORonce THEevery MODULAR two (2) days. BARN SeeDESIGN
also Chapter ..........................
4.3 for more 34
information
4.1 COW Habout milk storage.
Table4.1.2.
2. Milk production
Biogas per day as input to decide milk tank capacity
Digester ....................................................................................................................... 35
Average milk production (Lt)/day
No. cows
4.3 15
MILK PRODUCTION AND M20 25 30
ILK STORAGE ........................................................................................... 36
20 FEED AND 600
4.4 800
FEED STORAGE REQUIREMENTS 1,000 1,200
......................................................................................... 37
4.5
40 MANURE1,200PRODUCTION AND STORAGE ...............................................................................................
1,600 2,000 2,400 39
4.6
60 OTHER F1,800
ARM BUILDINGS AND 2,400 STORAGES3,000 ..........................................................................................
3,600 40
4.7
80 SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
2,400 3,200 4,000 4,800
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CONTENTS
3.2.6. Cows: Milk Production and Dimensions
Improved dairy management, in particular feeding and breeding, has an impact on cow
characteristics and needs. This in turn has implications on the cow house design, labour needs,
management
LIST OF TABLESskills.........................................................................................................................................
and other factors that relate to cow comfort and management. The table below 03
gives an overview on the dynamics at play in the herd and on the farm.
ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE
Table 3. ................................................................................................................................................
Attention list cow characteristics 05
Cow characteristic:
CHAPTER 1: INTRODUCTION Change over time: Impact:
.............................................................................................................. 07
Dimensions Will increase due to genetics The sizes of milk parlour entries and
CHAPTER 2: STRUCTURES, and better CONSIDERATIONS
young stock AND stands,IMPLICATIONS
stalls and the feed .................................
fence will need08
2.1 ACCESS TO PUBLIC rearing. to be adjusted accordingly.
UTILITIES ............................................................................................................... 08
FeedDintake
2.2 AIRY FARM LAY-OUT Increase of milk.....................................................................................................
PRINCIPLES production Bigger loads of feed will need to be put in09
2.3 DAIRY COW HOUSEcomes DESIGN from an increase in the feeding troughs, which results in
................................................................................................................ 10
2.4 EXAMPLE LAYOUT OF feed intake. DAIRY COW HOUSEmore
MODULAR work. Feed requirements increase 12
......................................................................
(production, purchase, storage).
Manure
2.6 production
TYPICAL FARM LAYOUT Higher AND milk production
FENCING = More manure storage is needed. Alleys 15
..............................................................................................
higher feed intake = higher might need to be scraped more often.
manure production Manure will be less dry and hence
3.1 MODULAR FARM DEVELOPMENT ........................................................................................................
different handling requirements. 16
3.2
NeedMfor comfort OF M
ANAGEMENT Higher
ODULAR milk FARM DEVELOPMENT
production PLAN ..............................................................
puts Prevention of hoof problems becomes 17
3.2.1. Capacity ofpressure the Milking on the
Parlourcow’s more important: comfortable stalls, dry 17
.............................................................................................
3.2.2. physical systems:
Manure Storage/Waste Water she works
Storage and flat flooring, no more than 2.5 hours 18
...................................................................................
3.2.3. Waiting Area (Holding Pen)
very hard. Cows have less ..................................................................................................
forced standing per day. Susceptibility for19
3.2.4. Treatment/Handling
buffer capacity of Cows and.................................................................................................
are more heat stress becomes higher. 19
3.2.5. Milk Storage ........................................................................................................................... 19
vulnerable.
Heat3.2.6. Cows: MilkFermentation,
Production anddigestion Dimensions and...............................................................................
Prevention and management of heat 20
3.2.7.
production Special Needs Cows ................................................................................................................
milk production produce a stress becomes more important. 21
3.2.8. Grouping of lotYoung
of heat. Stock
When .......................................................................................................
milk Providing shade and installing fans. 21
3.2.9. Water Supply ..........................................................................................................................
production increases, heat 21
3.2.10. Essential Points to Consider
production also increases. for each Module ........................................................................ 22
Moisture exhaustion Higher milk production Ventilation of the cows’ direct environ-
comes with higher exha- ment becomes more important.
3.4 FEED FENCE ........................................................................................................................................... 26
lation of moisture via the
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
respiration
In-heat period/ Higher milk production Heat detection requires a higher level of
3.4.3. Week-planning........................................................................................................................ 28
Heat detection reduces the length of visible accuracy, more awareness and more
in-heat period. accuracy.
Eating/lactating Cows with a genetically high Cows need to be very well managed and
CHAPTER 4: COST CALCULATIONS potential for milkFOR produc-THE MODULAR fed 24/7.BARN Nutrition DESIGNand care ..........................
of young 34
4.1 COW HOUSE CONSTRUCTION tion, have C a OSTS
high..................................................................................................
feed intake stock requires a higher level of manage- 34
4.1.1. Construction (almost
Costsimplying
Cow House that cows 1-4 ment
Modules skills and practice.
........................................................................ 34
4.1.2. produce milk until they drop
Biogas Digester ....................................................................................................................... 35
4.2 HERD DEVELOPMENT down) Young stock will
........................................................................................................................... 35
more easily get too fat (too
4.4 FEED AND FEED STORAGE high bcs). REQUIREMENTS ......................................................................................... 37
Metabolic
4.5 MANURE changes
PRODUCTION The transition
AND STORAGE from...............................................................................................
dry Management of transition cows needs 39
during transition period to lactation contains a more accuracy, skills and knowledge.
4.7 SUMMARY FARM STRUCTURE bigger change in meta-
MEASUREMENTS Transition cows require more comfort 41
.................................................................................
bolism. Transition cows and better care.
become more vulnerable.
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CONTENTS
3.2.7. Special Needs Cows
In Annex 2 (average number of animals present per module in pdf) the average number of special-
needs-cows on a weekly basis is shown, i.e. transition cows, calving cows, fresh cows, sick cows.
The need
LIST for separate
OF TABLES facilities for special-needs-cows largely depends on the level of cow comfort
......................................................................................................................................... 03
in the cow house. The modular design contains a high level of cow comfort and thus requires few
ABBREVIATIONS ....................................................................................................................................... 04
facilities for special-needs-cows. A calving-pen or a sick cow-pen will be sufficient for 95% of the
PREAMBLE
time. ................................................................................................................................................ 05
3.2.8.
CHAPTERGrouping of Young Stock
2: STRUCTURES, CONSIDERATIONS AND IMPLICATIONS ................................. 08
Grouping of young stock in herds up to 40 cows largely depends on coincidence. In a herd with 40
2.2 D AIRY FARM LAY-OUT PRINCIPLES ..................................................................................................... 09
cow lactating, on average 1 heifer calve is born every 20 days. In a herd with 80 lactating cows, on
2.3 DAIRY
average COWcalf
1 heifer HOUSE DESIGN
is born every................................................................................................................
10 days. When the farmer strives for a maximum of 4 weeks age 10
difference in a group, on a farm with 80 cows there are groups of maximum of 3 calves.
2.5 SUPPORT
Coincidence FUNCTIONS
has AND PHYSICAL STRUCTURES ........................................................................... 13
a big effect on these numbers, as in some periods there will be more calves born
compared to another. Or there will be more bull calves than heifer calves or vice versa (unless
sexed
CHAPTERsemen3:isCATTLE
used). When
BARN 5 heifer calves in
MODULAR a row are born,
APPROACH AND this has little impact
OPERATIONS on a farm with
............................ 16
200 cows. On a farm with 40 cows it has major impact. And the probabilities for this to happen are
the same on both farms!
The issues to address and to solve are: the dimensions of free stalls and feed fence, bullying of
small calves by dominant larger calves, and inseminations. Practically, the barn design needs to be
very flexible
3.2.3. regarding dimensions
Waiting Area (Holding of calves.
Pen) This is achieved with loose housing and a Swedish
.................................................................................................. 19
feed fence.
3.2.4. See Figures 17 and 18 in Annex 1.
3.2.5. Milk Storage ........................................................................................................................... 19
Since 3.2.6.
in the design
Cows:there is much feeding
Milk Production space available,
and Dimensions the risk of older calves bullying away
............................................................................... 20
younger/smaller
3.2.7. calves
Special canCows
Needs be controlled easily by good feed management. Prevention of feed
................................................................................................................ 21
selection is
3.2.8. the main target and providing enough feed is the second target.
Grouping of Young Stock ....................................................................................................... 21
Insemination
3.2.9. andWaterheat detection
Supply with these numbers of young stock is always aimed at individual
.......................................................................................................................... 21
young3.2.10.
stock. The farm Points
Essential management
to Consider should identify
for each Module the........................................................................
animals that need to be bred (use a cow- 22
calendar, measure girth circumference with a rope), mark them (colour mark, halter,
3.2.11. Management to Increase Number of Cows............................................................................. 22 chalk board,
etc.)
3.3 orDremember them, and
ESIGN OF FLOORS ANDinseminate them when they are in heat.
CUBICLES ..................................................................................................... 23
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.2.9. 3.4.2.
WaterSchedule
Supplyfor Barn Inspection Rounds .................................................................................... 27
3.4.3. Week-planning........................................................................................................................ 28
The mode of water supply is to be decided for each farm individually as access to piped water,
surface water, rainwater and a deep well or a borehole will vary from place to place. In designing a
system for rain water harvesting one shall take into consideration the rain fall pattern/seasonality,
CHAPTER
the 4: COST
daily water use and CALCULATIONS
the rain water storage. FOR THE In caseMODULARof extreme BARNrainfall DESIGN
the water ..........................
collection and 34
storage
4.1 COW system willCoverflow
HOUSE and the design should allow for proper discharge of excess water, in
ONSTRUCTION COSTS .................................................................................................. 34
such a4.1.1.
way thatConstruction
it does not cause
Costs Cow any House
problems Modulesto the1-4 day-to-day farm operations.
........................................................................ 34
4.1.2. Biogas Digester ....................................................................................................................... 35
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CONTENTS
Table 4. Rain water collection and usage
Module Number of Width Length Total Rain water Water usage cows: Lt/day(3)
cows metre metre surface m2 tanks(2)
(1)
20 OF TABLES
LIST 22 23 25 575 2 3,300
.........................................................................................................................................03
40 40 23 39 897 t.b.d. 6,000
ABBREVIATIONS
60 60 .......................................................................................................................................04
23 67 1,541 t.b.d. 9,000
80 80 23 78 1,794 t.b.d. 12,000
PREAMBLE ................................................................................................................................................05
1 = the amount of rainwater collected in litres equals the millimetres rainfall x the total surface. 2 = total number of
CHAPTER
rainwater 1: isINTRODUCTION
tanks per case to be decided (t.b.d.)..............................................................................................................07
and depends on rainfall, water usage and tank volumes. 3 = the water
usage of the cows is a rough estimate
Table
2.1 A5.CCESS
Example of rain
TO PUBLIC water collected
UTILITIES (Litres)
...............................................................................................................08
10 mm
2.2 rainFARMafter
DAIRY LAY-24hr 20 mm
OUT PRINCIPLES rain after 24hr 30 mm rain after 24hr
.....................................................................................................09
2.35,750
DAIRY COW 2,450 11,500 8,200 17,250 13,950
HOUSE DESIGN ................................................................................................................ 10
2.48,970 2,970 OF MODULAR
EXAMPLE LAYOUT 17,940DAIRY COW H11,940 26,910 20,910
OUSE ...................................................................... 12
2.5
15,410SUPPORT FUNCTIONS
6,410 AND PHYSICAL
30,820 STRUCTURES ...........................................................................
21,820 46,230 37,230 13
2.6
17,940TYPICAL FARM LAYOUT AND 35,880
5,940 FENCING ..............................................................................................
23,880 53,820 41,820 15
3.2.10.
3.1 MODULAREssentialFARMPoints to Consider........................................................................................................
DEVELOPMENT for each Module 16
Module 1: 20 cows
 The milking
3.2.2. parlour
Manure should beWater
Storage/Waste made suitable for extension with 2 milking places when
Storage................................................................................... 18
constructing
3.2.3. module
Waiting Area3 (60 cows).Pen) .................................................................................................. 19
(Holding
 The manure
3.2.4. transport canal should
Treatment/Handling be constructed in anticipation of moving to module 3 in the
of Cows................................................................................................. 19
near future.Milk
3.2.5. Or the
Storagedesign should be such that the manure transport canal can be easily dug 19
........................................................................................................................... in
the3.2.6.
existingCows:
floor Milk
whenProduction
constructing and module
Dimensions 3 (60 cows).
............................................................................... 20
 To3.2.7. Special
save costs, theNeeds
officeCows and ................................................................................................................
machine room do not necessarily need to be constructed in this 21
3.2.8. The
module. Grouping
space for of Young
erecting Stock .......................................................................................................
these structures in a later stage/module should however be 21
3.2.9. Water
marked and claimed. Supply.......................................................................................................................... 21
Module 3.2.11. Management to Increase Number of Cows............................................................................. 22
2: 40 cows
3.3 D ESIGN OF
 The cross alley FLOORS
at theAND far Cend UBICLES
can be .....................................................................................................
constructed without a roof over it, or it can be covered 23
3.4 with
FEED FENCE
simple ...........................................................................................................................................
temporary roof. 26
3.4.1. Breeding Bull(s)...................................................................................................................... 26
Module 3.4.2. Schedule
3/4: 60/80 cows for Barn Inspection Rounds .................................................................................... 27
3.4.3. Week-planning........................................................................................................................ 28
 The manure storage is removed and replaced by the holding pen.
 The manure transport canal is extended to the new manure storage behind the holding pen
(and optional spray race).
CHAPTER
 The milking 4: COST
parlour CALCULATIONS
is extended with FOR THE MODULAR
2 milking places, towards BARNthe outside..........................
DESIGN of the barn and 34
4.1 toward
COW H the new holding pen.
 A 4.1.1.
walk alley is constructed
Construction Costsnext CowtoHousethe new holding
Modules 1-4 pen.
........................................................................ 34
4.1.2. Biogas Digester....................................................................................................................... 35
3.2.11. Management to Increase Number of Cows
4.4 FEEDfarm
The dairy FEED STORAGE
ANDintends REQUIREMENTS
to increase the herd by.........................................................................................
at least 20 more cows shortly after the completion 37 of
4.5 M ANURE P RODUCTION AND S TORAGE ...............................................................................................
a module. The income from the extra milk production is used to pay off the investments. 39
4.6
BuyingOTHER FARMheifers
pregnant BUILDINGS
(closeAND STORAGES
to calving) ..........................................................................................
is the fastest and easiest way to increase the number 40 of
4.7 SUMMARY F ARM STRUCTURE M EASUREMENTS
cows. One should be aware that with the higher number .................................................................................
of cows, also the number of replacement 41
heifers increases. Bringing in animals from outside the herd and the farm carries the risk of
introducing infectious diseases such as: Page 1
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CONTENTS
 Bacteria (digital dermatitis, salmonellosis, mycoplasma)
 Viruses (IBR, BVD, BLV, FMD, RVF, etc.)
 Parasites (mange, lice, intestinal parasites, etc.)
LIST
Hence, OFthere
TABLES should .........................................................................................................................................03
be a programme for selection of healthy animals (certified-free of specific
infections) and placement
ABBREVIATIONS in a four week quarantine period in an isolated area on the farm, or in
.......................................................................................................................................04
another (isolated) place outside the farm. During this quarantine period, specific treatments and
PREAMBLE ................................................................................................................................................05
tests can be executed according to a herd biosecurity plan.
The young stock
CHAPTER facilities have space
1: INTRODUCTION for more animals than just the number of animals needed for
..............................................................................................................07
replacement. This requires use of the dry lot area outside the barn and more bedding material to
keep the loose housing resting-area dry.
2.1 same
The ACCESS
goes TOforPUBLIC
the cows’UTILITIESarea................................................................................................................08
The dry lot enables the farm staff to overstock relatively to the
2.2
number DAIRY FARM Lfor
of cubicles AY-aOUT PRINCIPLES
period of time,.....................................................................................................09
before the next growth step. In all modules it is possible to
2.3
createDmore COW H
AIRY space keepDhigher
toOUSE ESIGN ................................................................................................................
numbers of animals through the following approaches: 10
2.5 SUPPORT
 Construct theFUNCTIONS
area for the AND PHYSICAL
cows as designedSTRUCTURES in the...........................................................................
next module. This creates 20 extra cubicles 13
2.6thatTcan
YPICAL FARMtoLhouse
be used AYOUTdry AND FENCING
cows ..............................................................................................
and pregnant heifers. The area that becomes available in the 15
dry cow/young
CHAPTER 3: CATTLE stock BARNpart of MODULAR
the barn can be used to raise
APPROACH AND more young stock (or
OPERATIONS bulls).
............................ 16
 Construct the area for young stock as designed in the next module.
3.1 MODULAR
 Construct the F ARMmodule
next DEVELOPMENT and use........................................................................................................
the extra space for raising young stock and perhaps bulls 16 to
3.2get M ANAGEMENT
extra income. OF M ODULAR F ARM DEVELOPMENT PLAN .............................................................. 17
3.2.3.
3.3 Design of Waiting
FloorsArea and (Holding
CubiclesPen) .................................................................................................. 19
Considerations
3.2.5. Milk Storage ........................................................................................................................... 19
a.) Flooring
Stalls should be
3.2.7. comfortable
Special Needs Cows enough for high lactating cows to lay down at least 12 hours per day
................................................................................................................ 21
3.2.8.
in zero-grazing Grouping
systems.ofThe Youngmost Stock .......................................................................................................
important aspect of a stall is the flooring; this should be soft and 21
dry. It should also be non-skid to avoid slipping and falling when the cow lies down or gets up. 21
3.2.9. Water Supply..........................................................................................................................
3.2.10.
The barn plan Essential
has deepPoints bedded to Consider
free stalls. for There
each Module........................................................................
are stalls without a concrete floor that are filled 22
up with3.2.11.
bedding. Management to Increase Number of Cows............................................................................. 22
3.3 D ESIGN OF FLOORS AND
By far the best bedding materialCUBICLESis sand. .....................................................................................................
Second best, close to sand, are deep bedding materials 23
3.4
such asFEED
sawFENCE
dust, ...........................................................................................................................................
(chopped) straw, rice hulls, dried manure solids and other dry materials that do 26
3.4.1. Breeding Bull(s)......................................................................................................................
not lead to formation of hard lumps when used in the cubicles. 26
All in all, mattresses and mats are highly inferior to deep bedding materials because they are 27
3.4.3. wear
expensive, Week-planning........................................................................................................................
off and become harder over time. Rubber mats are usually close to being just 28 as
3.5 H YGIENE AND
hard as uncovered concrete. BIOSECURITY And................................................................................................................
mattresses and mats need a concrete surface underneath. Both 29
3.6 TREATMENT
mattresses and mats AND HANDLING
need good daily DAIRY CATTLE ....................................................................................
maintenance including use of drying materials such as saw 32
dust. Research
CHAPTER showsCALCULATIONS
4: COST that 5 cm of saw dust FOR should
THE MODULAR be used onBARN mattresses DESIGN and at least 10 cm on
.......................... 34
mats or concrete.
 Bring a high risk for the development of bruises, swellings and lesions on hocks and front
4.1.2. Biogas Digester....................................................................................................................... 35
knees of the cows. These cause pain, infections and lead to foot problems, stress and reduced
milk production.
 They provide little grip and a hard lying surface, and therefore hardly contribute to cow
comfort.
 They
4.6 alsoFdemand
OTHER the use of large amounts of bedding.
ARM BUILDINGS AND STORAGES .......................................................................................... 40
4.7 They require higher investments
SUMMARY FARM STRUCTURE (concrete, rubber/mattress).
MEASUREMENTS ................................................................................. 41
More information on floor design and construction is presented in Annex 1.

Page 1
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CONTENTS
b.) Headspace
The second most important aspect is to create sufficient head space for the cow to swing her head
when she lies down or gets up. The stall or cubicle needs a width of minimal 115 cm for a 135 cm
LIST cow.
high OF TABLES .........................................................................................................................................
Bigger cows need wider stalls. Optimal dimensions for modern HF cows (700 kg adult 03
weight): 122 cm wide,
ABBREVIATIONS 255 cm long, open head space, neck rail and brisket locator adjustable 04
....................................................................................................................................... in
position, distance neck rail and bedding minimal 1.30 cm. (confirm this dimension)
PREAMBLE ................................................................................................................................................ 05
c.) Design 1: INTRODUCTION .............................................................................................................. 07
CHAPTER
Deep bedding, 115 cm wide, 250 cm long. Neck-rail is adjustable. The Brisket locator is max. 5 cm
CHAPTER
above bedding2: STRUCTURES,
level and rounded, CONSIDERATIONS
position adjustable. AND size of the cows .................................
If theIMPLICATIONS increases, because 08 of
genetics,
2.1 ACCESS feeding
TO Por increased
UBLIC UTILITIES milk production, the size of the barn should be adapted as well. 08
............................................................................................................... In
this
2.2 barn,
DAIRY thisFARM
can beLAYdone
-OUTby putting the
PRINCIPLES neck rail and the brisket locator in a different position. 09
.....................................................................................................
d.)
2.4 Matching
EXAMPLE cow sizes with
LAYOUT OF Mstall
ODULAR dimensions
DAIRY COW HOUSE ...................................................................... 12
Cows
2.5 SUPPORT FUNCTIONS AND PHYSICALbigger,
in the herd and in groups can get STRUCTURES smaller, longer and shorter over time. Variation 13
........................................................................... in
dimensions
2.6 TYPICAL of Fanimals
ARM LAYOUTwithinAND a groupFENCING can have big impact on the use of stalls. When barns are too
.............................................................................................. 15
small, the large cows will not lay down enough and may lay with their hind parts outside the
stalls. Diagonally laying down is a clear signal that the resting area is too short, that there is not
3.1 MODULAR
enough head space FARM DEVELOPMENT
at the front, or that ........................................................................................................
the neck rail is too far backwards. When stalls are too big, 16
3.2 smaller
the MANAGEMENT
animals are MODULAR
OF likely FARM manure
to deposit DEVELOPMENT and urine PLAN in ..............................................................
the stalls. 17
Therefore,
3.2.1. onceCapacity
a year ofandthewhen
Milking indicated, there should be an assessment whether the cows still
Parlour ............................................................................................. 17
fit well3.2.2.
in the Manure
stalls andStorage/Waste
whether theWater stallsStorage
are still ...................................................................................
comfortable enough. Use the checklists in the 18
Cow Signals Checkbook for this. When there is much variation in cow size within a group, one can 19
divide3.2.4.
the group Treatment/Handling
into a large-cow of andCows .................................................................................................
a small-cow group, and to suit the stall dimensions for each 19
group. 3.2.5. Milk Storage ........................................................................................................................... 19
Use 3.2.7. Special Needs Cows ................................................................................................................ 21
 Deep 3.2.8.
bedding: Grouping of Young
sand, rice hulls,Stockchopped .......................................................................................................
straw, manure solids. 21
3.2.9. Water Supply.......................................................................................................................... 21
 Fill stalls weekly or minimal once every 14 days.
 Keep level of bedding above curb level.
 Inspect the stalls minimal 3x a day: remove wet bedding and manure, flatten the surface.
3.4 FEED FENCE ........................................................................................................................................... 26
Checkpoints
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
 All 3.4.2.
cows should be able
Schedule to stand
for Barn straight
Inspection with four
Rounds feet down in a stall. If not, move the neck rail
.................................................................................... 27
forward.
3.4.3. When there is much variation in cow size in a herd causing dirty stalls, split the herd
Week-planning........................................................................................................................ 28 in
3.5a small-cow
HYGIENEgroup and a large-cow group. Adjust stall dimensions accordingly.
AND BIOSECURITY ................................................................................................................ 29
3.6All T
cows
REATMENT ANDable
should be to lie down
HANDLING DAIRY straight
CATTLE in ....................................................................................
a stall. When too many cows lie diagonally, move 32
brisket locator forward.
CHAPTER
 Clean out4:manureCOSTand CALCULATIONS
wet bedding from FOR theTHE stallMODULAR
3-4 times perBARN day. DESIGN .......................... 34
 Ensure
4.1 COWthatHOUSEthe top 2-3 cm of theClast
CONSTRUCTION OSTS meter of the stall bedding is dry.
.................................................................................................. 34
 Level of
4.1.1. bedding should not be lower than the curb. If so, the bedding should be
Construction Costs Cow House Modules 1-4 ........................................................................ 34flattened. When
there is not enough
4.1.2. bedding
Biogas Digester for this, bedding should be added.
....................................................................................................................... 35
Page 1
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CONTENTS
LIST OF TABLES .........................................................................................................................................03

ABBREVIATIONS .......................................................................................................................................04
PREAMBLE ................................................................................................................................................05
Good practice:
CHAPTER 1: examples of well-dimensioned
INTRODUCTION and comfortable free stalls with deep bedding.
..............................................................................................................07
CHAPTER 2: STRUCTURES, CONSIDERATIONS
Poor AND IMPLICATIONS
practice: .................................08
Cows have problems lying down on
2.1 hard surfaces. This brings stress and health problems
ACCESS TO PUBLIC UTILITIES ...............................................................................................................08
2.2 and as a result a reduced milk production.
DAIRY FARM LAY-OUT PRINCIPLES .....................................................................................................09
2.3DAIRY COW HOUSE DESIGN ................................................................................................................ 10
2.4EXAMPLE LAYOUT OF MODULAR DAIRY COWMattresses are expensive and do not create 12a
HOUSE ......................................................................
2.5SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES comfortable resting surface. Deep bedding that 13
........................................................................... is
2.6 maintained well on a daily base, is far better
TYPICAL FARM LAYOUT AND FENCING .............................................................................................. 15 for the
cows, and will bring more milk and more health
3.2.2. Poor practice: Because of the wall, the cow that wants
Manure Storage/Waste Water Storage................................................................................... 18
3.2.3. to stand up cannot lunge her head forward and has
3.2.4. problems getting up. The standing cow has
Treatment/Handling of Cows................................................................................................. 19 problems
3.2.5. lying down because of the same reason. The wall also
Milk Storage ........................................................................................................................... 19
3.2.6. Cows: Milk Production and Dimensions blocks ventilation.
............................................................................... 20
3.2.9. Water Supply.......................................................................................................................... 21
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Poor practice: When the stalls are not comfortable the
Breeding Bull(s)...................................................................................................................... 26
3.4.2. cows will more often ly down elsewhere to rest.
Schedule for Barn Inspection Rounds .................................................................................... 27
3.4.3. Resting in dirty places brings stress, less milk
Week-planning........................................................................................................................ 28 and
higher risks for mastitis and wounds.
.
4.1.2. Biogas Digester....................................................................................................................... 35
4.5 MANURE
Further readingPon AND STORAGE
free stall (cubicles,
RODUCTION beds) ...............................................................................................
constructions 39
4.6 OCow
Books: FARM BUILDINGS
THER Signals the Basics,AND
Cow STORAGES ..........................................................................................
Signals Building for the Cow, Cow Signals Checkbook, Cow 40
4.7 S F
Signals Hoof Signals.
UMMARY ARM STRUCTURE M EASUREMENTS ................................................................................. 41
Websites: Extension America’s Research-based Learning Network and Cow Comfort and health
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CONTENTS
3.4 Feed Fence
Considerations
The feed fence stops cows from stepping into the feed. A self-locking feed fence is used to catch
cows OF
LIST andTABLES
to fixate .........................................................................................................................................03
them for treatments. The feed fence includes a neck rail (post-and-rail barrier).
Feed fences should be adapted to the dimensions of the cows. If not, the cows will develop bumps
ABBREVIATIONS .......................................................................................................................................04
(acquisite bursae) and wounds. A self-locking feed fence is a good investment on farms with 40 or
PREAMBLE
more cows, as it................................................................................................................................................05
reduces time to catch cows and it facilitates handling of groups of cows. On farms
with fewer cows the benefits are less.
CHAPTER 1: INTRODUCTION From an economical point of view, farmers with less than 40
..............................................................................................................07
cows can choose not to install self-locking feed fences. The only argument, besides price, against
CHAPTER 2: STRUCTURES,
putting in place a self-locking feed CONSIDERATIONS
fence, is that cows AND can beIMPLICATIONS
too big for a certain .................................08
size feed fence.
Design
A
2.3 DAIRYfeed
Swedish COWfence
HOUSE never touches
DESIGN the neck of the cow, but stops the animals at the shoulder.
................................................................................................................ 10
This feed fence matches with
2.4 EXAMPLE LAYOUT OF MODULAR DAIRYcows of almost COW allHsizes. The only issue is with young calves that
OUSE ...................................................................... 12
might step through it. Neck rails almost always give rise to the development of shoulder
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 bumps.
See
2.6 anTexample of a Swedish
YPICAL FARM LAYOUT ANDfeed F fence
ENCING in figure 17 and 18, in annex 1.
.............................................................................................. 15
Management
Cows
3.1 M should
ODULAR beFlocked in a feed fence
ARM DEVELOPMENT for as short as possible because forced standing creates
........................................................................................................ 16
excessive pressure onOF
3.2 MANAGEMENT the
Mhooves,
ODULARand FARM thus stress and pain.
DEVELOPMENT PLAN .............................................................. 17
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.9. Water Supply.......................................................................................................................... 21
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Wrongly
Poor practice: Breedingdesigned
Bull(s)......................................................................................................................
or constructed feed troughs and feed fences force the animals to perform 26
unwanted behaviour, like standing in the feed and contaminating it with manure. 27
3.4.3. Week-planning........................................................................................................................ 28
3.5 H YGIENE
More information AND onBIOSECURITY ................................................................................................................
feed fence design and construction is presented in Annex 1. 29
Further reading
Books: Cow Signals the Basics, Cow Signals Building for the Cow, Cow Signals Feeding Signals.
4.1 COW
Website: HOUSE CONSTRUCTION COSTS .................................................................................................. 34
www.roodbont.com
4.1.2. Biogas Digester....................................................................................................................... 35
4.2 HERD
3.4.1. DEVELOPMENT
Breeding Bull(s) ........................................................................................................................... 35
Considerations
Some M
4.5 farmers
ANURE want to have AND
PRODUCTION a breeding
STORAGE bull. In most cases this bull will serve only some of the
............................................................................................... 39
cows
4.6 in oestrus,
OTHER FARMwhile the majority
BUILDINGS AND Sof the cows
TORAGES are artificially inseminated. Housing bulls on solid
.......................................................................................... 40
floors Sand
4.7 in freeFARM
UMMARY stallsSTRUCTURE
creates a lot of work as regards
MEASUREMENTS to providing them with dry resting places.
................................................................................. 41
When their resting places are too wet, the bulls will build up dirt crusts on their sides that can give
rise to skin infections. It is very dangerous to house a bull together with the cows!
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CONTENTS
Housing a bull or bulls
Options for housing a single breeding bull:
 In a separated pen next to the dry cows.
 In a pen located at the far end from the milking parlour or in a pen created in the dairy cow
LIST OF TABLES ......................................................................................................................................... 03
barn.
 In a special pen built
ABBREVIATIONS on the side of the dry lot, or created by segregating a part of the dirt lot.
....................................................................................................................................... 04
Feeding this bull requires bringing feed to him.
PREAMBLE ................................................................................................................................................ 05
Mating plan1: INTRODUCTION .............................................................................................................. 07
CHAPTER
Option 1: Next to the dry cows
The cow in oestrus can be tied in the separation pen and the bull can be brought to this cow led by
a2.1person.
ACCESSTheTO PUBLIC
best UTILITIES
and most safe ...............................................................................................................
option for this is when the bull has a nose ring. The second best 08
2.2 Dis
option FARMWhen
a halter.
AIRY LAY-OUT the Pbull has served
RINCIPLES .....................................................................................................
the cow he is led back to his pen. 09
2.4 EXAMPLE
Option 2: Mating LAYOUT OF M
in the dirt ODULAR DAIRY COW HOUSE ...................................................................... 12
lot
2.5 option
Best SUPPORT FUNCTIONS
is to AND PHYSICAL
make a temporary pen inSTRUCTURES
the dirt lot,...........................................................................
in which the cow in oestrus is put. Then the 13
2.6 isTreleased
bull YPICAL Fin, ARM LAYOUT
both cow and ANDbull FENCING
can be..............................................................................................
loose. Ensure they cannot go into the barn. 15
After
CHAPTER a certain time, separate
3: CATTLE BARNthe cow from the
MODULAR bull by chasing
APPROACH AND the bull into the............................
OPERATIONS barn and leaving 16
the cow in the dirt lot. Lead the cow back into the herd.
3.2
Option M3:ANAGEMENT
Special penOF inM dirt lotFARM DEVELOPMENT PLAN .............................................................. 17
ODULAR
the
In this3.2.1.
situation Capacity of the
a special Milking Parlour
self-locking feed fence.............................................................................................
for a bull should be put in place. Here the bull17 is
3.2.2. Manure Storage/Waste Water Storage
locked before the cow is put in, and after he has mated with the cow. ................................................................................... 18
Letting 3.2.4. Treatment/Handling
cows being mated by the bull of Cowsin the.................................................................................................
dirt-lot requires a specific gating plan that is required 19
3.2.5. Milk Storage ...........................................................................................................................
to safely and easily separate the bull and the cow. As a bull can be very aggressive when a person 19
wants to separate him from a cow, special attention must be given concerning gate positions and 20
possible exit/escape routes before entering the dirt-lot. The head and neck of mature bulls can be 21
too big for a self-locking feed fence sized for dairy cows. In this case, a special self-locking feed
3.2.9. Water Supply.......................................................................................................................... 21
fence for a bull is needed and highly recommended.
Putting bull and cow loose in a pen with a solid floor can easily lead to slipping, falling and
trauma of both bull and cow. Cleaning the pen and/or stalls can best be done when the bull is
locked in the feed fence, away for mating or tied up.
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.2. 3.4.2. Schedule
Schedule for Barn
for Barn InspectionRounds
3.4.3. Week-planning........................................................................................................................ 28
ConsiderationsAND BIOSECURITY ................................................................................................................ 29
3.5 H YGIENE
3.6 TREATMENT
Barn rounds serveAND HANDLING
for daily management DAIRY CofATTLE ....................................................................................
the stables and cow checks. The person doing the barn 32
inspection rounds
CHAPTER 4: COST goes in between the FOR
CALCULATIONS animals.THEThese MODULAR roundsBARN are standardized, to ensure that
DESIGN .......................... 34
every worker follows the same routine operational procedure in which nothing is forgotten.
4.1 barn
Four HOUSE are
COWrounds CONSTRUCTION
performed every COSTSday, ..................................................................................................
two (2) big rounds and two (2) small rounds. The barn 34
rounds 4.1.1.
alwaysConstruction
start on theCosts
sameCow point House
and Modules
at the same 1-4 ........................................................................
time. The rounds end where they started. 34
4.1.2. Biogas Digester .......................................................................................................................
The material (stall cleaner, bedding material) is stored here. 35
4.2 H ERD DEVELOPMENT ........................................................................................................................... 35
Because the person doing the barn round goes in between the cows and gets his boots dirty with
4.3
manure,MILK PRODUCTION
at the end point ANDhe mustMILK beSTORAGE
able to clean ...........................................................................................
boots and/or to change boots. 36
4.4 F EED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37
The barn rounds can very well be combined with pushing-up feed towards the feed fence. Almost
4.5
always MitANURE PRODUCTION AND STORAGE ............................................................................................... 39
is most logical to first push-up the feed and then do the barn round. The feed push-up
4.6 OTHER FARM
will stimulate cowsBUILDINGS
to stand up AND STORAGES .......................................................................................... 40
and go to the feed fence. As a result more stalls will be empty
which offers a good moment to observe cow behaviour (oestrus detection, cows not active/not
eating well).
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CONTENTS
Table 6. Barn inspection round schedule

Barn round Chore Remarks
1. Major: Before or  Complete treatment of stalls Cleaning of
LIST OF TABLES .........................................................................................................................................
immediately after  Clean floor in cross alleys and other indicated cross alleys 03
milking
ABBREVIATIONS places must be done
....................................................................................................................................... 04
 Check all cows for oestrus (dry cows: calving) shortly before
PREAMBLE ................................................................................................................................................ 05
 Check each cow for behaviour, health, feed intake, the alleys are
CHAPTER 1: INTRODUCTION scraped
issues .............................................................................................................. 07
 Tasks that come on specific days: - clean water
troughs two times per week
2.1 TO PUBLIC
ACCESSBefore
2. Minor: or U  Clean...............................................................................................................
TILITIES stalls 08
2.2 after
DAIRY F
lunch ARM L AY - OUT P RINCIPLES .....................................................................................................
 Check cows for oestrus (dry cows: calving) 09
2.3 DAIRY COW HOUSEDESIGN Scan ................................................................................................................
cows for behaviour, health, issues 10
2.4 E XAMPLE LAYOUT OF M ODULAR
3. Major: End of the  Treatment of stalls D AIRY C OW H OUSE ...................................................................... 12
2.5 afternoon
SUPPORT FUNCTIONS  AND Clean PHYSICAL
floor SinTRUCTURES
cross alleys ...........................................................................
and other indicated 13
2.6 TYPICAL FARM LAYOUTplaces AND FENCING .............................................................................................. 15
CHAPTER 3: CATTLE BARN  Check all cows for

MODULAR oestrus (dryAND
APPROACH cows:OPERATIONS
calving) ............................ 16
 Check cows for behaviour, health, feed intake, etc.
4. Minor:
3.2 MANAGEMENTEvening  Clean stalls
OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
Combined
(last round)
3.2.1. Capacity oftheCheck Milking cows
Parlour with feed push
for .............................................................................................
oestrus (dry cows: calving) 17
3.2.2.  Scan cows
Manure Storage/Waste for behaviour,
Water health, issues. up
Storage................................................................................... 18
Further reading
Books:3.2.5.
Cow Signals Robotic
Milk Storage Milking, Cow Signals Dry cows, special needs and treatments, Cow
........................................................................................................................... 19
Signals Building
3.2.6. for the
Cows: MilkCow. Website:
Production andwww.roodbont.com
Dimensions ............................................................................... 20
3.4.3. 3.2.9.Week-planning
Water Supply.......................................................................................................................... 21
Considerations
3.3strict
A planning
DESIGN structure of the work helps to ensure that prevention and maintenance chores are
OF FLOORS AND CUBICLES ..................................................................................................... 23
actually performed, like foot bathing, vaccination, cleaning, replacing oil, ordering supplies, etc.26
3.4 FEED FENCE ........................................................................................................................................... It
also reduces
3.4.1. the possibilities
Breeding Bull(s)that work is forgotten, like drying-off of a cow on the correct date. 26
......................................................................................................................
Essential
3.4.3.building stones for ........................................................................................................................
Week-planning effective planning and follow up 28
a) Agenda and white board
3.6 InTthe office theAND
REATMENT following
HANDLING should DAIRY be in place: .................................................................................... 32
CATTLE
 The week planning printed and attached to the wall for all employees to be visible.
CHAPTER 4: COST
 A calendar or CALCULATIONS
agenda with ample FOR spaceTHE MODULAR
for making notes.BARN DESIGN .......................... 34
4.1  CA OWwhite
HOUSE board, on which the
CONSTRUCTION COSTS events and actions that are not in the normal week planning
.................................................................................................. 34
are written
4.1.1. down. Costs Cow House Modules 1-4 ........................................................................ 34
Construction
4.1.2. Biogas Digester ....................................................................................................................... 35
4.2
b) AHfixedERD D work schedule........................................................................................................................... 35
EVELOPMENT
4.3 ForMILK PRODUCTION
dairy AND MILK STORAGE
herds of approximately sixty ...........................................................................................
cows and more, it is essential to apply a fixed and 36
4.4 disciplined
FEED AND Fwork EED Splanning.
TORAGE REQUIREMENTS
Routine activities .........................................................................................
should be planned on the same days of each 37
4.5 week.
MANURE PRODUCTION
With smaller numbersAND STORAGE of cows ...............................................................................................
on the farm a routine work schedule is of less 39
4.6 importance,
OTHER FARM dueBUILDINGS
to the fact AND that STORAGES
less numbers ..........................................................................................
of people are involved and activities may vary 40
4.7 more
SUMMARY FARMto
from week STRUCTURE
week (some MEASUREMENTS
weeks there will .................................................................................
be no cows calving, no cows to be dried off, 41
etc.). To establish a structured work schedule it is recommended to apply a Week-Planner and
White Board. See an example in Figure 4 below.
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CONTENTS
LIST OF TABLES ......................................................................................................................................... 03

ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
Figure 4. Week Calendar and White Board
2.5 SHygiene
3.5 UPPORT FandUNCTIONS
BiosecurityAND PHYSICAL STRUCTURES ........................................................................... 13
Considerations
Hygiene at the farm is of utmost importance in all operations. Hygiene covers amongst others the
3.1 MODULAR
following aspectsFARM DEVELOPMENT
of dairy farming: ........................................................................................................ 16
3.2.1. hygiene
a) Personal Capacity of the Milking Parlour ............................................................................................. 17
3.2.2.
The design makes Manurethe Storage/Waste
milk room theWater logical Storage
and only...................................................................................
entry to the dairy barn. Here boots, overalls 18
and cleaning facilities for hands, materials and boots can be placed. There is a fully equipped toilet 19
3.2.4.a washing
including Treatment/Handling
basin. of Cows ................................................................................................. 19
3.2.5. Milk Storage ........................................................................................................................... 19
b) Environmental hygiene
This concerns cleaning and tidying of the grounds and drainage. The organized structure of the
design makes it easy to mow grass and offers very few places where people want to put unused or
3.2.9. Water Supply.......................................................................................................................... 21
rarely used materials and equipment, and junk. Manure should not leak or run off outside
designated
3.2.11.areas. All building
Management structures
to Increase Number must be equipped
of Cows with floor drains in order to drain
............................................................................. 22
waterDfrom
3.3 floors, washing basins, CIP, toilets etc. Drainage water must be separated from toilets
ESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23
(human
3.4 FEEDexcrements and CIP water including lye and acid).
FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
c) Bio-security
 Prevention
3.4.3. of infections entering
Week-planning the herd
........................................................................................................................ 28
The modular design has one entrance to the farm, with the option of a separate entrance for the
3.6 cows to the pasture
TREATMENT AND H(if present).
ANDLING Having
DAIRY CATTLEonly....................................................................................
one entrance enables good control and overview 32
over trucks, cars and persons entering the farm. Nobody from outside the farm should be able
CHAPTER
to have 4: COST
contact CALCULATIONS
with the animals, unless FORafter THEproper MODULAR hygienic BARN
measures, DESIGN ..........................
i.e. washing of hands 34
4.1 orCwearing
OW HOUSE gloves and wearing
CONSTRUCTION COSTSfarm clothing (boots, overalls). Preferable the farm 34
.................................................................................................. is
surrounded
4.1.1. with a fence that prevents people and animals coming in.
Construction Costs Cow House Modules 1-4 ........................................................................ 34
 Reduction
4.1.2. and
Biogasprevention of the spread of infections within the herd
Digester ....................................................................................................................... 35
4.2 This
HERDaspect of biosecurity
DEVELOPMENT has many dimensions:
........................................................................................................................... 35
4.3 M ILKEarly detection,
PRODUCTION AND isolation
MILK Sand TORAGE effective treatment of cases of possibly infectious diseases.
........................................................................................... 36
4.4 FEED Segregation
AND FEED STORAGEof groups of animals. This
REQUIREMENTS is difficult to achieve on farms with less than 100
......................................................................................... 37
4.5 MANURE cows, although a AND
PRODUCTION goodSTORAGE
attempt ...............................................................................................
is made with the calves that drink milk. These are first 39
4.6 OTHER housed
FARM individually
BUILDINGS AND in pens,
STORAGES and thereafter in groups separated from the older animals.
.......................................................................................... 40
 Vaccination
4.7 SUMMARY FARM Sand TRUCTUREeradication of infectious
MEASUREMENTS diseases.
................................................................................. 41
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CONTENTS
d) Milking hygiene
This concerns hygienic milking procedures and hygienic handling and storage of milk.
 Milking parlour: The milking parlour offers an infrastructure in which best practices are
LIST OF TABLES ......................................................................................................................................... 03
supported:
 1 cloth for every
ABBREVIATIONS cow
....................................................................................................................................... 04
 Teat dipping after milking
PREAMBLE
 Cleaning ................................................................................................................................................
of the stand underneath the udder 05
 Good
CHAPTER 1: view on the udder, good
INTRODUCTION light
.............................................................................................................. 07
 Comfort for the cow
2.1 General
ACCESSbarn TO Pdesign:
UBLIC UTILITIES ............................................................................................................... 08
2.2  DPlacement
AIRY FARM of LAY -OUT PRINCIPLES ..................................................................................................... 09
lights
2.3  DHygienic
AIRY COWproperties
HOUSE DESIGN of the ................................................................................................................
floor underneath the udder: it should be possible to rinse 10 or
2.4 EXAMPLE LAYOUTmilk
swipe manure, OF M and
ODULARwaterDaway AIRY COW HOUSE ...................................................................... 12
2.5  SUPPORT
EnoughFspace, AND PHYSICAL
no potentially
UNCTIONS harmful STRUCTURES
constructions ...........................................................................
for the cow 13
Milk room:
CHAPTER The milkBARN
3: CATTLE room offers
MODULAR all facilities
APPROACHfor cleaning AND of milking
OPERATIONS equipment, milk cans and
............................ 16
other milk storage equipment.
TableM
3.2 7.ANAGEMENT
Milk-room OF M ODULARand
facilities FARM DEVELOPMENT PLAN .............................................................. 17
requirements
3.2.1. Capacity of the Milking Parlour ............................................................................................. 80 17
3.2.2. Manure Storage/Waste Water Storage 20...................................................................................
Cows 40 Cows 60 Cows
Cows18
3.2.3. module module module
module
Daily3.2.4. Treatment/Handling
milk production (Lt): of Cows .................................................................................................
400 800 1,200 1,600 19
3.2.5.Requirements:
Milk Storage ........................................................................................................................... 19
A. 3.2.6.Aluminium
Cows: Milk Production
milk-cans (Cap. 50 and Lt)Dimensions 10 ...............................................................................
20 - - 20
B. 3.2.7. Special Needs Cows
Milk cooling tank (Cap. 2 Tonnes)................................................................................................................
- - 1 1 21
3.2.8.Incl. CIP
Grouping
/ Milkofdispatch
Young Stock pump) ....................................................................................................... 21
C. 3.2.9.Machine-room (condenser/vac)
Water Supply - - 1 1
.......................................................................................................................... 21
(high) voltage
3.2.10.o Essential Pointselectric
to Considerpowerfor each Module ........................................................................ 22
D. 3.2.11.Hot water boiler to Increase Number of 1Cows.............................................................................
Management 1 1 1 22
3.3E. DESIGN Washing basin for
OF FLOORS ANDmilk-cans: 1 1 1 -
CUBICLES ..................................................................................................... 23
o Pre-rinse (cold)
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1.o Washing
Breeding(hot)
Bull(s) ...................................................................................................................... 26
o
3.4.2. After rinsefor
Schedule (cold)
Barn Inspection Rounds .................................................................................... 27
o Dry-rack (milk-cans)
3.4.3. Week-planning........................................................................................................................ 28
F. Utilities: 1 1 1 1
o Desk w/cabinet (small tools)
3.6 TREATMENT o Scale AND HANDLING DAIRY CATTLE .................................................................................... 32
(milk-cans)
StrainerCALCULATIONS
CHAPTERo4: COST with sieve FOR THE MODULAR BARN DESIGN .......................... 34
G. Floor Drainage of water 1 1 1 1
4.1.1.
Critical controlConstruction Costs Cow
points as regards to the House
above Modules
table are: 1-4 ........................................................................ 34
4.1.2. Biogas Digester
a) Washing basins section ....................................................................................................................... 35
4.2 InH ERD DEVELOPMENT ........................................................................................................................... 35
this room the following equipment/facilities are located or available:
 Washing basins to clean aluminium milk-cans (pre-rinse cold/hot cleaning/cold post-
rinse)
 Dry rack holder (for milk-cans)
 Availability of hot and cold water
Page 1
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CONTENTS
b) Milk-room
In this room the following equipment is located:
 Milk cooling tank
 CIP/milk-dispatch pump
LIST
 OF TABLES
Milk .........................................................................................................................................
cleaning system/basins 03
 Hot and cold.......................................................................................................................................
ABBREVIATIONS water (taps) 04
PREAMBLE
c) Machine room ................................................................................................................................................ 05
In this room
CHAPTER the following equipment
1: INTRODUCTION is located:
.............................................................................................................. 07
 Electric power back-up (separate fuel storage outside building)
 Vacuum pumps milking machine
CCESS TO PUBLIC
2.1  ACondenser UTILITIES ............................................................................................................... 08
unit (milk-tank)
2.2  DHot FARMboiler
AIRYwater LAY-OUT PRINCIPLES ..................................................................................................... 09
2.3  DElectrical
AIRY COWswitch
HOUSEboard DESIGN ................................................................................................................ 10
2.4  EXAMPLE
Storage cabinet (oil M
L AYOUT OF andODULAR DAIRY COW HOUSE ...................................................................... 12
spare parts)
d) Office
In this room
CHAPTER the following
3: CATTLE BARNequipmentMODULAR is located:
APPROACH AND OPERATIONS ............................ 16
 Desk set with storage facilities for parts, medicines (refrigeration)
 Fridge (milk samples)
 Small spare parts storage
e) Toilets
In3.2.4.
this room the following equipment
Treatment/Handling is located:
of Cows ................................................................................................. 19
Toilets Milk
 3.2.5. including
Storage washing basin
........................................................................................................................... 19
Table
3.2.7.8. Special
Separate Needs(room)Cowsstructures typical measurements (indicative m2)
................................................................................................................ 21
Structure
3.2.8. m 2
13.2.9.
Washing basin
Water Supply(milk-cans) 12
.......................................................................................................................... 21
23.2.10.
Milk-room
Essential Points to Consider18 for each Module ........................................................................ 22
33.2.11.
Machine room
Management to Increase Number 16 of Cows............................................................................. 22
3.3 4DESIGN
OfficeOF FLOORS AND CUBICLES .....................................................................................................
9 23
3.4 5FEED FENCE
Toilets ...........................................................................................................................................
w/washing closet 4 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.2.
Essential Schedule
building stones forfor
Barn Inspection Rounds .................................................................................... 27
hygiene/biosecurity
 Only 3.4.3. Week-planning
one single entry to........................................................................................................................
the farm for people, trucks, cars, etc. A gate around the farm, that 28
3.5 keeps
HYGIENE AND B IOSECURITY
persons and animals out. ................................................................................................................ 29
3.6 When
TREATMENT
cows haveAND HANDLING
access to pasture,DAIRY theCATTLE
pasture ....................................................................................
should also be fenced-off for persons and cattle 32
of all ages.
CHAPTER Also dogs
4: COST and wild animals
CALCULATIONS FOR should
THEbe stopped to BARN
MODULAR get in. DESIGN .......................... 34
 Planned set up of the farm buildings and driveways, so mowing of grass is easy and there are
4.1 noCplaces where junk or unused materials and equipment is stored.
 Treatment of animals must be an easy and safe job, under circumstances that make good
4.1.2. Biogas Digester ....................................................................................................................... 35
quality of work possible. For herds up to 80 cows all treatments can be well organized and
performed in cubicles or in the feed fence, including vaccinations and hoof trimming. Udder
treatments are best performed in the milking parlour.
 Calves up to 4-6 months of age should be housed separately and not mixed with older animals.
Young calves suffering from diarrhoea should be separated from other young calves, which
can be achieved by solitary housing.
 The barn(s) with animals should have one logical entry. Before entering the barn there should
be a space for washing hands, disinfecting booths and with overalls for visitors and staff.
Page 1
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CONTENTS
 The milk room must be equipped with necessary facilities for cleaning of milking equipment,
milk collection materials and with facilities for correct storage of milk. It should be a functional,
safe and comfortable place to work. Cleaning must be very easy (smooth floors). There should
LIST
beOF places for.........................................................................................................................................
no TABLES entry and staying for mice and rats. 03
The milking parlour
ABBREVIATIONS should be a safe and comfortable working environment (light,
....................................................................................................................................... 04
temperature, noise, constructions, space) both for people and for cows.
PREAMBLE ................................................................................................................................................ 05
Management
The actual level of hygiene highly depends on management, maintenance, awareness and routines.
The planning should have fixed events for:
ACCESS TO PUBLIC UTILITIES ............................................................................................................... 08
2.1 Cleaning
2.2 D AIRY FARM
 Managing LAY-OUT PRINCIPLES ..................................................................................................... 09
supplies
2.3 DAIRY COWof
 Maintenance Hequipment
OUSE DESIGN and................................................................................................................
facilities 10
2.4 E XAMPLE LAYOUT OF M ODULAR
 Training and instruction, including consultancy D AIRY C OW H OUSE ...................................................................... 12
2.5 SUPPORT Fof
 Monitoring UNCTIONS
hygiene,AND PHYSICAL
diseases STRUCTURES
and infection risks............................................................................ 13
Further reading
Books: Cow Signals the Basics, Cow Signals Building for the Cow, Cow Signals Dry cows, special
3.1 M
needs ODULAR
cows FARM DEVELOPMENT
and treatments, Cow Signals ........................................................................................................
Udder Health Large Herd Edition. 16
3.2 M ANAGEMENT OF M ODULAR F ARM D EVELOPMENT
Websites: www.roodbont.com and google on “bio-security dairy cows”. P LAN .............................................................. 17
3.2.3.
3.6 Treatment Waiting Area (Holding
and Handling Dairy Pen) .................................................................................................. 19
Cattle
Considerations
3.2.5. Milk Storage ........................................................................................................................... 19
On several
3.2.6. occasions
Cows: Milk andProduction
for various andreasons
Dimensions cows...............................................................................
need to receive medical treatment. When the 20
facilities and procedures are good, cow handling and treating is a safe job that can be performed 21
3.2.7. Special Needs Cows ................................................................................................................ in
3.2.8.
a well-controlledGrouping
manner, of Young
leadingStock to the .......................................................................................................
following two objectives: 21
3.2.9.
 Treat a cowWater
as soonSupply ..........................................................................................................................
as possible after diagnosis of the nature and cause of an illness. 21
 Give preventive treatments according to the planning. for each Module ........................................................................ 22
3.3 D ESIGN
Essential OF FLOORS
building stonesAND CUBICLES .....................................................................................................
for treatments and handling of cows 23
3.4
Cows Fmust
EED FbeENCE ...........................................................................................................................................
well positioned in good facilities for treatment. What is considered good depends 26
3.4.1. Breeding Bull(s) ......................................................................................................................
partly on the treatment that needs to be given. The treatment process must ensure minimal (dis-) 26
stress for the cow. This depends partly on the treatment facilities and partly on the way the 27
animals3.4.3.
are putWeek-planning
in the facility, ........................................................................................................................
handled and herded (herdmanship). 28
Management
For cow4:barns
CHAPTER COST that are designed for aFOR
CALCULATIONS capacity to house up to
THE MODULAR BARNapproximately 100 cows, a self-
DESIGN .......................... 34
locking feed fence is the best facility for many treatments, for example: vaccinating, fertility
checks and inseminating. An important issue that requires attention when using a self-locking
feed gate, isBiogas
4.1.2. that cows should
Digester not be left standing locked-in for periods longer than 45 minutes.
....................................................................................................................... 35
4.2 InHaERD
barnDEVELOPMENT
that is designed to house over 40 cows a separation pen is created, in which a self-
........................................................................................................................... 35
4.3 locking
MILK P feed fence is installed and used to fixate a cow.
RODUCTION AND MILK STORAGE ........................................................................................... 36
 InFbarns
4.4 EED ANDdesigned
FEED Sto house Rup
TORAGE to 40 cows, .........................................................................................
EQUIREMENTS the farm staff can work well by catching cows in the 37
free stalls, and/or by using halters to fixate them.
4.6 Hoof trimming requires the most specific treatment facility or structure.
OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40
Page 1
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CONTENTS
The following activities can be organized in a free-stall at the different sections/locations:
 Dry cow treatment: Cows can be separated after being milked in the parlour. Immediately after
LIST OF TABLES
milking time, they .........................................................................................................................................
are herded back into the parlour where they are given dry cow treatment. 03
Hoof trimming (individual
ABBREVIATIONS cows): In the wooden free-stalls a rope is used to tilt up the hind
....................................................................................................................................... 04
legs or the front legs. In the iron free-stalls, one free-stall can be equipped with a hoof trimming
PREAMBLE
construction. ................................................................................................................................................
Or a special mobile hoof trimming chute can be used. 05
Hoof trimming
CHAPTER (group treatments):
1: INTRODUCTION In farms with up to 40 cows, it is advised not to hoof-trim
.............................................................................................................. 07
the whole herd at one day, but to do the hoof trimming based on a plan (strategic trimming):
 Every cow at drying off
2.1  AEvery
CCESS TOcow PUBLIC
at 80-100 UTILITIES
days in ...............................................................................................................
milk 08
2.2  DEvery
AIRY FARM
cow thatLAY-shows
OUT PRINCIPLES
signs of hoof .....................................................................................................
problems 09
2.3 When
DAIRY COW HOUSE
specialized hoofDESIGNtrimming................................................................................................................
services are available through a trained external service 10
2.4 provider,
EXAMPLEgroup LAYOUT OF MODULAR
trimming will beDthe AIRYbest COW HOUSE ......................................................................
approach. The person who offers this service will 12
2.5 bring
SUPPORT FUNCTIONS
his own hoof trimmingAND PHYSICAL chute. SIn herds over
TRUCTURES ...........................................................................
40 cows, the farmer can choose between 13
2.6 either
TYPICAL FARMtrimming
strategic LAYOUT AND FENCING
or group ..............................................................................................
trimming. Group trimming needs a free-stranding hoof 15
trimming
CHAPTER 3: chute.
CATTLE BARN MODULAR APPROACH AND OPERATIONS ............................ 16
 Vaccinations: When a self-locking feed fence is available, one should vaccinate cows when all
3.1 areMlocked
ODULAR in.FARM
If a D EVELOPMENT
self-locking feed........................................................................................................
fence is not in place, the cows can be locked very closely 16
3.2 together
MANAGEMENT OF M ODULAR F ARM D EVELOPMENT P LAN ..............................................................
in the barn for vaccination. In herds over 40 cows, the track going to the holding pen 17
can be usedCapacity
3.2.1. to vaccinate of the cows.
Milking Parlour ............................................................................................. 17
 Clipping cows: Tie up the cow with Water Storageor
a halter, ...................................................................................
lock her up in the self-locking feed gate. 18
 Intra-mammary treatments: In the milk parlour, during milking.
 Intra-uterine treatments: In the self-locking feed gates or in a free-stall. In the self-locking gates,
3.2.5. Milk Storage ........................................................................................................................... 19
it is most helpful to lock-in cows next to the cow that is treated. These cows block the sideways
movements of the cow that needs treatment.
 Clinical
3.2.8. investigation,
Grouping of Young operations Stockand treatments by a vet: Best place and setting is chosen by
....................................................................................................... 21
the3.2.9.
vet. This will either be in the lactating herd, in the calving pen or outside the pen.
Water Supply.......................................................................................................................... 21
 Calving
3.2.10. help: This isPoints
Essential done to inConsider
the calving pen.Module ........................................................................ 22
for each
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester ....................................................................................................................... 35
Page 1
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CONTENTS
CHAPTER 4: COST CALCULATIONS FOR THE MODULAR BARN DESIGN
This chapter gives a summary of the cost of construction of the modular cow house design (4.1).
LIST to that,.........................................................................................................................................
OF TABLES
In addition it presents data and forecasts on herd development (per age group), expected 03
milk production, feed
ABBREVIATIONS requirements and manure production for each module. These data are
....................................................................................................................................... 04
indicative and merely serve as example to stress the importance of the need for forward planning.
PREAMBLE ................................................................................................................................................ 05
Forward
CHAPTER planning is essential in ..............................................................................................................
1: INTRODUCTION a situation where the farmer has a clear growth strategy. The 07
information will assist in timely investments to assure sufficient capacity as regards to animal
housing, milk storage/chilling and transport, manure management, feed storage and fodder
2.1 ACCESSThe
production. TO Platter
UBLIC UTILITIES
requires ...............................................................................................................
a fodder cultivation plan that includes type of fodder crops grown 08
2.2 numbers
and DAIRY FARM LAY-required
of acres OUT PRINCIPLES
based on .....................................................................................................
herd size and anticipated expansion one year down the 09
line.
4.1
2.6 T Cow House
YPICAL FARM Construction
LAYOUT AND Costs
FENCING .............................................................................................. 15
CHAPTER
The design 3: CATTLE
drawings forBARN
the modularMODULAR cow house APPROACH are presented in Annex 3. The............................
AND OPERATIONS local consultants 16
who
3.1 were
MODULAR engaged
FARM inDthe compilation
EVELOPMENT of this Handbook, prepared BOQs and costings for the
........................................................................................................ 16
construction of the modules 1-4,
3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT at Kenyan prices and locally available building materials. Detailed
PLAN .............................................................. 17
BOQs3.2.1.
and construction
Capacity ofcost calculations
the Milking Parlour are presented in Annex 4 for each module. A detailed
............................................................................................. 17
BOQ and3.2.2. cost Manure Storage/Waste Water Storageis...................................................................................
calculation for a biogas digester presented in Annex 5. The tables below give18a
summary3.2.3.of the construction
Waiting costs for
Area (Holding the..................................................................................................
Pen) cow house modules and a biogas digester. 19
3.2.5. Milk Storage ........................................................................................................................... 19
4.1.1. 3.2.6.
Construction
Cows: Milk Costs Cow House
Production Modules ...............................................................................
and Dimensions 1-4 20
Table 9 gives the construction costs for each module in KES. The figures are indicative as prices of
building materials
3.2.9. Watermay differ
Supply per region, depending on availability and source of origin. For each
.......................................................................................................................... 21
module 3.2.10. Essential Points to“wood”
a price is given for Considerand for Module
for each “steel” ........................................................................
to allow for different choice in building 22
materials Timber is cheaper but less durable. Steel on the other hand needs good
3.2.11. Management to Increase Number of Cows............................................................................. 22 care to protect it
against corrosion (especially caused by manure).
3.4 FEED FENCE ........................................................................................................................................... 26
Table3.4.1.
9. Approximate cow......................................................................................................................
Breeding Bull(s) house construction costs in Kenyan Shillings (KES) 26
Material
3.4.2. Schedule for Barn Timber Steel
3.4.3. Total Per cow Total Per cow
Week-planning........................................................................................................................ 28
Phase
3.5 H1: 20 cows
YGIENE AND BIOSECURITY4,866,000 243,300 6,450,000 322,500
................................................................................................................ 29
Phase
3.6 2: 40 cows AND HANDLING
TREATMENT 7,841,750
DAIRY CATTLE 196,044 10,224,750 255,619
.................................................................................... 32
Phase 3: 60 cows 10,627,000 177,117 13,815,000 230,250
Phase 4: 80 cows 13,032,750 162,909 16,989,750 212,372
4.1 detailed
See HOUSE CONSTRUCTION
COWconstruction costs in Annex 4COSTS .................................................................................................. 34
Figure4.1.2.
5 on the next Digester
Biogas page shows the lay-out of the 4-modular cow house design for illustration
....................................................................................................................... 35
purposes.
4.2 HERD Other design drawings
DEVELOPMENT and a 3D presentation are provided in Annex 3.
........................................................................................................................... 35
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CONTENTS
LIST OF TABLES ......................................................................................................................................... 03

ABBREVIATIONS ....................................................................................................................................... 04
PREAMBLE ................................................................................................................................................ 05
Figure3.2.5.
5. CowMilkhouse modular
Storage design with 20 cows per module
........................................................................................................................... 19
4.1.2. 3.2.8.
Biogas Digester
3.2.9. Water Supply.......................................................................................................................... 21
In the3.2.10.
event a Essential
biogas unit is considered,
Points to Consider for a typical
each Module design and BOQ of the construction materials22–
........................................................................
including indicative
3.2.11. pricelist
Management - are shown
to Increase Number in ofAnnex 5. The design drawings show four different
Cows............................................................................. 22
capacities, viz. 4, 6, 9 and 13 m 3. The estimated construction costs are shown in the table below.
3.4 FEED FENCE ........................................................................................................................................... 26
Table3.4.1.
10. Biogas estimated
Breeding construction cost
Bull(s) ...................................................................................................................... 26
Capacity
3.4.2. 4m 3
Schedule for Barn Inspection Rounds 6m3 ....................................................................................
9m3 13m3 27
Building materials
3.4.3. 30,485 46,443 55,962 66,756
Week-planning........................................................................................................................ 28
Biogas
3.5 materials
HYGIENE 2,730 ................................................................................................................
AND BIOSECURITY 1,560 1,560 2,460 29
Company
3.6 fees AND HANDLING
TREATMENT 11,028 DAIRY CATTLE 14,568 16,644 19,140
.................................................................................... 32
Totals 44,243 62,571 74,166 88,356
4.2 Herd Development
4.1.2. Biogas Digester ....................................................................................................................... 35
As
4.2 mentioned in the introduction
HERD DEVELOPMENT of this chapter, in case a farmer wishes to expand his dairy farm
........................................................................................................................... 35
and has a clear growth strategy, he needs to do forward planning. Expansion of
4.3 MILK PRODUCTION AND MILK STORAGE ........................................................................................... 36 the herd has
various
4.4 FEED implications
AND FEED Sin terms Rof
TORAGE housing and
EQUIREMENTS feeding requirements, but – of course - also 37
......................................................................................... as
regards to milkPproduction
4.5 MANURE RODUCTIONand ANDstorage.
STORAGE As for cow housing, the number of animals per different
............................................................................................... 39
age
4.6 groups
OTHERhaveFARM different housing
BUILDINGS AND Srequirements, including measurements. This has its impact on
TORAGES .......................................................................................... 40
the
4.7 design
SUMMARYof theFARM
stableSTRUCTURE
interior and the layout of the
MEASUREMENTS cow house. The table below illustrates – in41a
.................................................................................
typical example - what happens to the herd size and composition when moving from module 1 to
module 4. The young stock that is part of the herd in the example below is only replacement stock.
Page 1
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CONTENTS
Table 11. Herd development (established situation)
Scenario 20 cows 40 cows 60 cows 80 cows
Pos.* Neg. Pos. Neg. Pos. Neg. Pos. Neg.
Cows in lactation 20 20 40 40 60 60 80 80
CowsOF
LIST dryTABLES .........................................................................................................................................03
2 2 4 4 6 6 9 8
Pregnant heifers ** 0 0 1 1 1 1 1 1
Total lactating + Dry.......................................................................................................................................04
ABBREVIATIONS 22 22 45 45 67 67 90 89
Calves
PREAMBLE 1 1 3 4 3 3 4 4
................................................................................................................................................05
Weaned – 6 months 1 1 3 3 4 4 6 6
CHAPTER
7 – 12 months 1: INTRODUCTION 2 ..............................................................................................................07
2 5 5 7 7 9 10
13 – introduction
CHAPTER 2: STRUCTURES, 4 CONSIDERATIONS 9 9 AND18 IMPLICATIONS 13 27 .................................08
17 37
Pregnant heifers 3 3 5 5 8 8 10 10
2.1
TotalA young TO PUBLIC UTILITIES
CCESSstock 11 ...............................................................................................................08
16 25 35 35 49 46 67
2.2
TotalD AIRY FARM LAY-OUT34PRINCIPLES
head 39 .....................................................................................................09
73 84 105 119 140 160
*2.3
Pos. =Dscenario:
AIRY COW age H at OUSE
first calving
DESIGN 24 ................................................................................................................
months, calving interval: 420 days and replacement 20%. 10
*2.4
Neg. = scenario: age at first
EXAMPLE LAYOUT OF MODULAR calving 36 months,DAIRY calving
COW interval:
HOUSE 460 days and replacement 20%.
...................................................................... 12
** Pregnant heifers 6 weeks before calving.
The herd development table presents two scenarios: viz. a scenario reflecting the number of
CHAPTER 3: CATTLE
animals in the BARN MODULAR
desired situation (subscript “Pos”) APPROACH and a second AND OPERATIONS
less desirable scenario ............................
(subscript 16
“Neg”). See for more
3.1 MODULAR FARMdetailed information
DEVELOPMENT Annex. 2 Dairy Herd Number Calc Tables. The Annex
........................................................................................................ 16
includes an example of reports that can
3.2 MANAGEMENT OF MODULAR FARM DEVELOPMENT be generated byPLANVetvice showing treatments in relation 17
.............................................................. to
herd size.
4.3 Milk Production and Milk Storage
3.2.5. Milk Storage ........................................................................................................................... 19
Forecasting milk production is not only required from a financial point of view (sales and income)
but also for logistical reasons, in terms of milk storage and milk transportation. Table 12 shows
annual and daily production for the 4 modules and for 2 average production levels (with Pos/Neg.
scenario).
3.2.9. Water Supply.......................................................................................................................... 21
Table3.2.11.
12. Milk Production
Management to (indicative)
Increase Number of Cows............................................................................. 22
Scenario 20 cows 40 cows 60 cows 80 cows
3.3 DESIGN OF FLOORS AND C
Pos. UBICLES Neg......................................................................................................
Pos. Neg. Pos. Neg. Pos. Neg. 23
3.4
BasedFon
EED FENCE
average ...........................................................................................................................................
production of 7,000 litres milk/cow/year: 26
3.4.1.
Annual Breeding
milk production Bull(s)......................................................................................................................
(Lt) 133,833 122,196 273,750 249,946 407,583 372,141 547,500 494,33726
Average per daySchedule
3.4.2. (Lt) for Barn367 Inspection 335Rounds ....................................................................................
750 685 1,117 1,020 1,500 1,35427
3.4.3. Week-planning........................................................................................................................ 28
Based on average production of 4,000 litres milk/cow/year:
Annual milk production (Lt) 76,476 69,826 156,429 142,826 232,905 212,652 312,857 282,478
3.6 TREATMENT
Average per day (Lt)AND HANDLING 210 DAIRY 191CATTLE ....................................................................................
429 391 638 583 875 77432
The forecast of milk volumes is of particular importance to timely invest in the required storage
and COW HOUSE
4.1 capacity and Ctransport
ONSTRUCTION COSTS .................................................................................................. 34
of raw milk. Use of aluminium milk-cans (cap. 50 Lt.) may be an
economical way of collecting and storing the fresh milk up to 1,000 litres per day. In this case the
4.1.2. Biogas Digester....................................................................................................................... 35
raw milk should be dispatched twice daily to a receiving party that is equipped with a chilling
tank (e.g. a processor). It is not advisable to store milk overnight at the farm without chilling!
The installation of a milk cooling tank may be considered once milk volumes reach in excess of 1
ton per day (replacing the aluminium milk cans). While determining the required milk storage
capacity of a milk chilling tank, consideration must also be given to the duration that milk can be
stored at the farm. For example if milk is stored for 2 days, the milk storage capacity must equal 2
x 1,600 Lt = 3,200 Lt for scenario 80 cows (Pos.*).
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CONTENTS
4.4 Feed and Feed Storage Requirements
Feed requirements and storage capacity also increase when a farmer expands the herd and moves
from module 1 to 4.
LIST OF TABLES ......................................................................................................................................... 03
a.) Feed ration
ABBREVIATIONS ....................................................................................................................................... 04
The required storage capacity for forages - e.g. silage and hay – is largely determined by the feed
PREAMBLE
ration ................................................................................................................................................
and the herd size. The feed ration gives insight in the different types of forages that are used 05
on the farm1:and
CHAPTER whether these concern
INTRODUCTION fresh or preserved fodder (such as maize/grass silage 07
.............................................................................................................. or
hay). An important parameter in this respect is the total daily dry matter (DM) intake or
CHAPTER 2:for
requirement STRUCTURES,
each different group CONSIDERATIONS
of animals categorized AND IMPLICATIONS
by age or type (e.g. .................................
lactating cows, dry 08
cows,
2.1 Apregnant
CCESS TO P heifers,
UBLIC Ucalves TILITIESetc.), and the actual dry matter content of the different feeds
............................................................................................................... 08
(including
2.2 DAIRY forages)
FARM Lused AY-OUT in the ration. ..................................................................................................... 09
PRINCIPLES
In
2.3 order
DAIRYto Cachieve
OW HOUSE an Doptimum milk production, the feed ration must be determined 10
ESIGN ................................................................................................................ in
consultation with an animal feed nutritionist. Based on the available feed
2.4 EXAMPLE LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12 ingredients, feed prices
and
2.5 nutritional
SUPPORT Fvalues
UNCTIONS of theAND different
PHYSICAL feed ingredients,
STRUCTURES an optimum feed ration can be calculated
........................................................................... 13
pegged on an estimated/desired level of milk production. In the table below an example is shown
of such a dairy feed ration, based on an average milk production of 7,400 kg/dairy cow.
Table
3.1 M 13. Typical
ODULAR FARM example
DEVELOPMENT of a feed........................................................................................................
ration 16
3.2 MANAGEMENTKilogramme OF MODULAR DryFARMMatter (DM) ration PLAN .............................................................. 17
DEVELOPMENT
3.2.1. Cows
Capacity of the MilkingCows Parlour 0 .............................................................................................
– 3mth 4 – 6mth 7 – 12mth 13–15mth Pregnant17
Feed 3.2.2.
name lactating dry calves calves Calves heifers
Manure Storage/Waste Water Storage................................................................................... heifers 18
Lucerne 1.95 0.40 1.00 1.00 1.00
Maize silage 7.80 3.40 1.00 1.00 1.00 2.10
Rhodes grass hay 1.95 1.70 1.00 0.40 1.00 1.00 1.00
3.2.5. Milk Storage ........................................................................................................................... 19
Napier grass hay - 5.00
Oats straw 0.50
Total forages 12.20 10.10 1.00 1.80 3.00 3.00 4.10
3.2.9. Water Supply.......................................................................................................................... 21
Maize grain 3.40 0.75 1.00 1.00 1.50 1.00
Wheat bran 1.70 1.70 1.00 1.00 1.00
Wheat pollard
3.3 DESIGN OF FLOORS
Soy bean meal 1.70
AND CUBICLES ..................................................................................................... 23
0.75 1.00 1.00 0.50
3.4 F EED FENCE
Sunflower cake ...........................................................................................................................................
0.90 0.50 1.00 26
3.4.1. Breeding
Lupine seed meal 0.90 Bull(s) ......................................................................................................................
1.70 26
3.4.2.
Limestone Schedule
0.06 for Barn Inspection Rounds .................................................................................... 27
3.4.3.
Sodium BicarboWeek-planning
0.12 ........................................................................................................................ 28
3.5 H YGIENE
Mineral mix AND B
0.19IOSECURITY ................................................................................................................
0.20 0.03 0.03 0.05 0.07 29
3.6 T REATMENT AND
Total concentrate 8.07 H ANDLING 3.60 D AIRY C ATTLE
1.50 ....................................................................................
2.03 3.03 3.55 3.07 32
DM intake/head
CHAPTER 21.17
4: COST 13.70
CALCULATIONS 2.50 THE MODULAR
FOR 3.83 6.03
BARN 6.55 ..........................
DESIGN 7.17 34
4.1 feed
The HOUSE
COWration CONSTRUCTION
can also be based Con OSTS the..................................................................................................
whether the farmer targets a maximum or an optimum 34
4.1.1.
milk production.Construction
The maximumCosts CowmilkHouseproductionModules 1-4 attainable
level ........................................................................
with the breed on the farm, may 34
not lead to the highest profitably or “margin” for the farmer. This is e.g. the case when aiming 35
4.1.2. Biogas Digester ....................................................................................................................... at
4.2 HERDproduction
maximum DEVELOPMENTmay...........................................................................................................................
disproportionally increase the cost of feeding as a share of the total cost 35
4.3 MILK
of milk PRODUCTION
production. The AND MILKmilk
optimum STORAGE ...........................................................................................
production may be well below the maximum or potential 36
4.4 F EED AND F EED STORAGE R EQUIREMENTS .........................................................................................
milk production of the cow however profitability of the dairy enterprise may be higher. 37
4.6 OTHER
b.) Total feedFrequirement
ARM BUILDINGS AND STORAGES .......................................................................................... 40
4.7 SUMMARY FARM Sherd
Based on the expected TRUCTURE MEASUREMENTS
development (see Table .................................................................................
11) and the feed ration-in-place (see Table 13), 41
the total (annual) feed requirement can be calculated. Care must be given to cater for harvest, feed
and storage losses. Page 1
Page 37
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CONTENTS
An example of the annual feed requirement of an 80 cows farm module (module 4) is presented in
Annex 6. For each feed ingredient or forage in the feed ration, the total storage capacity is derived
from taking the figures for the total weight in dry matter (DM) and the average weight per cubic
LIST
meter.OF TABLESis.........................................................................................................................................
Reference made to Tables 14 and 15 for the required storage capacity for maize silage and 03
lucerne hay respectively
ABBREVIATIONS for module 4 (80 cows).
....................................................................................................................................... 04
PREAMBLE
 Silage storage ................................................................................................................................................ 05
Silage
CHAPTER is stored in a bunker preferably
1: INTRODUCTION made of concrete (floor and walls). The measurements
.............................................................................................................. 07
(length, width, height) of the bunker depend on the amount of silage that needs to be kept over a
certain period of time and the feeding needs or feeding speed per day. As a rule of thumb every
day
2.1 about
ACCESS2 meters
TO PUBLICshould be fed ...............................................................................................................
UTILITIES out of the silage bunker to prevent quality losses. 08
In
2.2theDexample
AIRY FARM presented
LAY-OUTinPAnnex RINCIPLES 6, a.....................................................................................................
total of 269 tonnes dry matter of maize silage is required 09
per
2.3 annum
DAIRY(868COWtonsHOUSE x D 31%ESIGN DM................................................................................................................
= 269 tons). In order to calculate the required size of the silage 10
bunker(s)
2.4 it is Lnecessary
EXAMPLE AYOUT OFto know the
MODULAR DAIRYreference
COW Hstandard of product DM kg/m3 in relation 12
OUSE ...................................................................... to
different
2.5 SUPPORTbunker sizes (width
FUNCTIONS AND and height).STRUCTURES ........................................................................... 13
PHYSICAL
As
2.6 per the example
TYPICAL FARM Lof the above
AYOUT AND Fmentioned annual feed requirement (maize silage, Annex 6)15a
ENCING ..............................................................................................
sample calculation of the required maize silage bunker space is presented in the table below.
3.1 M
Table 14. Maize
ODULAR FARM
silage DEVELOPMENT
bunker measurements ........................................................................................................
(without soil cover) 16
3.2
Side M height
ANAGEMENTKg. Dry MODULAR
OFMatter per metreFARM DEVELOPMENT
length bunker with PLANwidth ..............................................................
of: 17
3.2.1. Capacity of the Milking Parlour .............................................................................................
DM Net DM 17
metres 3.2.2. 8 metre Storage/Waste
Manure 9 metre
Water Storage 10...................................................................................
metre kg/m3 -5% * kg/m3 18
1.5 3.2.3. 3,530
Waiting Area (Holding 3,970 4,410 245 12.3 233
Pen) .................................................................................................. 19
1.8 3.2.4. Treatment/Handling4,740 of Cows .................................................................................................
5,250 250 12.5 238 19
2.0 3.2.5. Milk Storage ...........................................................................................................................
5,280 5,865 255 12.8 242 19
Maize silage harvest
269 tonnes DM (see Annex 6) ………… 269,035 total kgs of DM annually (80 cows + young stock)
3.2.9. Water Supply.......................................................................................................................... 21
Divided by NetEssential
3.2.10. DM kg/m 3 (233) …......
Points to Consider 1,156
for eachmModule
3 silage bunker capacity required (269,035 / by 233)
........................................................................ 22
Total 3.2.11.
length of Management
……………………...…... 96 metres silage bunker
to Increase Number of Cows............................................................................. 22
3.3 DESIGN OF FLOORS AND CUBICLES 3.....................................................................................................
number of silage bunkers 23
3.4 FEED
Practical FENCE
length ...........................................................................................................................................
+/- 30 – 40 mtr ………. 32 metres length per silage bunker 26
3.4.1. Breeding Bull(s) ......................................................................................................................
1 additional length (silage bunker ends) 26
3.4.2. Schedule for Barn Inspection 99 Rounds ....................................................................................
metres total length required (in metres) 27
3.4.3. Week-planning........................................................................................................................ 28
(*) = correction is made to silage density in Kenyan situation of -5%.
 Hay storage
Hay
CHAPTER is stored in a hay
4: COST shed or barn, which
CALCULATIONS FOR usually
THE MODULAR is a simpleBARN open DESIGN
structure ..........................
with a roof. The 34
measurements of the hay shed depend on the amount of hay that needs to be kept over a certain
period of time. In the example of Annex 6 a total of 156 tonnes of dry matter of Lucerne and
Rhodes grass hay
4.1.2. Biogasis Digester
required per annum (respectively Lucerne 88 ton x 85% = 75 ton DM and
....................................................................................................................... 35
Rhodes
4.2 HERD grass 96 ton x 85% ...........................................................................................................................
DEVELOPMENT DM = 81 ton DM, total 156 ton DM). 35
In order
4.3 MILKto Pcalculate the required measurements of the hay shed one needs to know the average
weight
4.4 FEED in dry matter per cubic metre of hay. In this example this is put at 180 kg of DM per m3.
AND FEED STORAGE REQUIREMENTS ......................................................................................... 37
Based
4.5 MANURE the
on this, required measurement
PRODUCTION of the hay shed for Lucerne and Rhodes grass for the 80
AND STORAGE ............................................................................................... 39
cow
4.6 module/feed
OTHER FARMration BUILDINGS presented in Annex 6, is shown in the Table 15.
AND STORAGES .......................................................................................... 40
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CONTENTS
Table 15. Hay storage capacity
Tn DM Tn Product Kg/m3 Totals
Annual production:
- Lucerne hay 75 88 180 488 m3
- Rhodes
LIST grass hay
OF TABLES 81 96 180 531 m3
......................................................................................................................................... 03
1,019 m3
ABBREVIATIONS
Number of hay sheds: .......................................................................................................................................
1 X 04
Capacity per hay
PREAMBLE shed: 1,019 m3
................................................................................................................................................ 05
metres
CHAPTER 1: INTRODUCTION ..............................................................................................................
m3 w l h 07
Storage capacity
CHAPTER and measurements
2: STRUCTURES, per hay shed:
CONSIDERATIONS AND IMPLICATIONS 1,100 10 22 5
................................. 08
4.5
2.2 D Manure
AIRY FARM Production
LAY-OUTand Storage ..................................................................................................... 09
PRINCIPLES
Manure
2.4 EXAMPLE production
LAYOUT OF MODULAR DAIRY COW HOUSE ...................................................................... 12
In order to calculate
2.5 SUPPORT FUNCTIONS the ANDrequired
PHYSICAL manure storage ...........................................................................
STRUCTURES capacity, the manure production of each 13
different animal per age-group must be known and the level of milk production per dairy cow. 15
2.6 TYPICAL FARM LAYOUT AND FENCING ..............................................................................................
In Table 16 an example is given of the average annual manure production (m3) per animal age-
CHAPTER
group with 3: an CATTLE
average milkBARN MODULAR
production of 7,500 APPROACH
kg/lactation. AND OPERATIONS ............................ 16
It
3.1should
MODULARbe notedFARMthat total manure
DEVELOPMENT production and storage capacity depend on the farming
........................................................................................................ 16
system
3.2 that is in place.
MANAGEMENT OF M For
ODULARexample FARM free grazing or semi-zero-grazing
DEVELOPMENT versus full zero-grazing
PLAN .............................................................. 17
makes3.2.1.
a huge Capacity
difference.
of theInMilking
the given example
Parlour it is assumed that all animals are housed in the
............................................................................................. 17
stable3.2.2.
all year round.
ManureHowever,
Storage/Waste an allowance
Water Storage of minus-25% in the total annual manure collection18
................................................................................... is
applied, due toWaiting
3.2.3. the factArea
that(Holding
the lactating herd has access to a free walking area. Furthermore, it19
Pen) .................................................................................................. is
assumed that the
3.2.4. manure of calvesof(age
Treatment/Handling Cows0–3 months) is collected separately and does not enter the
................................................................................................. 19
3.2.5. collection/storage
main manure Milk Storage ...........................................................................................................................
facility. 19
Table3.2.7.
16. Manure Specialproduction
Needs Cowsper ................................................................................................................
annum 21
3.2.8. Grouping of Young Stock .......................................................................................................
Avg. animals present Production m 3 21
Animal type / Water Supply ..........................................................................................................................
3.2.9. Scenario Scenario 21
age group m3*
3.2.10. Essential loss**
Points toloss Considertotalfor each 20 Module 40 ........................................................................
60 80 20 40 60 80 22
Mature cows 18 25% 4.5 13.5 22 45 67 89 300 601 901 1,202
3.2.11. Management
0 – 3 months*** 0 25%
to Increase
- -
Number1of Cows2.............................................................................
3 4 - - - -
22
3.3 D ESIGN
4 – 6 months OF FLOORS
3.2 25%AND C UBICLES
0.8 2.4 .....................................................................................................
2 3 5 6 4 7 11 14 23
3.4
7 – 12 Fmonths
EED FENCE8...........................................................................................................................................
25% 2.0 6.0 2 5 7 9 14 27 41 54 26
13 – 153.4.1.
months Breeding
11 25% 2.8 8.3 4 9 13 17 35 70 105 140 26
Bull(s) ......................................................................................................................
Pregnant heifers
3.4.2. 11 25% 2.8 8.3 3 5 8 10 21 41
Schedule for Barn Inspection Rounds ....................................................................................62 83 27
38.4 Total per year (m3) 373 746 1,119 1,493
3.4.3. Week-planning........................................................................................................................
Loss (m3) 3% 11 22 34 83
28
3.5 HYGIENE AND BIOSECURITY ................................................................................................................
Collected per year (m ) 3 362 724 1,086 1,448 29
3.6 TREATMENT AND HANDLING DAIRY CATTLE Avg. ....................................................................................
collected per day (m3) 1.0 2.0 3.0 4.0 32
* = based on an average 7,000 kg/milk/cow and 100% summer feeding.
CHAPTER
** = loss due to4:freeCOST
walkingCALCULATIONS
in sand or soil yards. FOR THE MODULAR BARN DESIGN .......................... 34
*** = manure from calves (age 0 – 3 months) is handled separately (as solids).
Manure storage capacity
4.1.2. Biogas Digester ....................................................................................................................... 35
The farmer not only needs to know the daily/monthly volumes of manure produced by the herd
in the cow barn, he also needs to plan for sufficient storage capacity. This not only depends on the
volume produced by the cows, but also on the use of the manure. For example whether this is to be
applied on the land where forage or other crops are grown, it is fed into a biogas digester, or gets
sold to third parties. The latter is not uncommon in Kenya, especially for farmers in peri-urban
areas with little land.
The intended use of the manure has implications for choices and investments as regards to the
structures and facilities needed for storage and management. In the example provided in Table 17
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CONTENTS
the assumption is that the manure is used to fertilize the arable land of the dairy farm. Since
manure cannot be distributed on the land all year round due to cropping- and rainy-seasons, it is
essential to know the period that manure must be stored. In the example given below a period of
180 days is taken.
LIST OF TABLES ......................................................................................................................................... 03
Table 17. Manure.......................................................................................................................................
ABBREVIATIONS storage (used as fertiliser) 04
Required collection & storage capacity Scenario 20 40 60 80
Mixing tank ................................................................................................................................................
PREAMBLE 3 days m3 3 6 9 1205
Total production
CHAPTER 183 days (0.5 year) m3 181 362
1: INTRODUCTION .............................................................................................................. 543 724 07
Storage buffer capacity 20 % m3 36 72 109 145
Required total storage m3 217 434 652 869
capacity
2.3
TankDmeasurement
AIRY COW HOUSE DESIGN ................................................................................................................
required w l h m3 10
2.4 EXAMPLE
Mixing tank: LAYOUT OF MODULAR DAIRY 2.0COW3.0 HOUSE 1.0......................................................................
6 6 6 6 12
2.5 SUPPORT
1. Storage FUNCTIONS
tank 20 cows: AND PHYSICAL S10.0 TRUCTURES 9.0 ...........................................................................
2.5 225 13
2.6 TYPICAL
2. Storage FARM
tank LAYOUT AND FENCING10.0
40 cows: ..............................................................................................
17.0 2.5 425 15
3. Storage3:tank
CHAPTER 60 cows:
CATTLE BARN MODULAR 10.0 17.0 2.5 AND OPERATIONS ............................
APPROACH 638 16
4. Storage tank 80 cows: 10.0 23.0 2.5 863
4.6 3.2.1. Capacity
Other Farm Buildingsof the Milking
and Storages Parlour ............................................................................................. 17
In Chapter
3.2.3. 2.4Waiting
a number Area of(Holding
other farm Pen)structures and buildings have been mentioned, which are
.................................................................................................. 19
essential for a professional
3.2.4. Treatment/Handling commercial of Cows dairy farm.
................................................................................................. 19
3.2.5.
This includes Milk
for Storage
example ...........................................................................................................................
a feed store where dairy concentrates, minerals and other feed 19
ingredients are stored, either in bulk or in bags. Here also usually milling (if applicable) and 20
mixing of the different feed ingredients take place. It is important to avail sufficient space for this 21
3.2.8.and Grouping
feed store for storage of Young
of the Stockdairy.......................................................................................................
meals produced (or purchased) to complement the forages 21
3.2.9. Water Supply ..........................................................................................................................
in the feed ration. This feeds store needs a robust weather proof design, should be lockable and 21
well insured (including the goods stored inside). for each Module ........................................................................ 22
Other3.2.11. Management
farm structures thattoneed Increaseto be Number of Cowsin
considered .............................................................................
the farm plan are buildings for storing 22 of
3.3 D ESIGN OF FLOORS AND C UBICLES .....................................................................................................
agricultural inputs like fertilisers, seeds and chemicals and small tools. In addition to that, a shed 23
3.4 FEED FENCE
for parking ...........................................................................................................................................
and safe-keeping of farm machinery - and a workshop for maintenance and repairs 26
3.4.1. Breeding Bull(s) ......................................................................................................................
and storage of spare parts and lubricants - needs to be present on the farm. 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester ....................................................................................................................... 35
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CONTENTS
4.7 Summary Farm Structure Measurements
The table on the next page gives a summary is of the main farm structures and recommended
measurements as presented in this Handbook for each module.
LIST OF TABLES ......................................................................................................................................... 03
Table 18. Farm structures measurements (summary) indicative in metres
ABBREVIATIONS ....................................................................................................................................... 04
Scenario
PREAMBLE ................................................................................................................................................
Name farm structure 20 40 60 80 05
Silage bunker
CHAPTER 1: :INTRODUCTION ..............................................................................................................
1 l 25 50 74 99 07
w 2 4 6 8
CHAPTER 2: STRUCTURES, CONSIDERATIONS
h 1.5 AND
1.5IMPLICATIONS
1.5 ................................. 08
1.5
m 298 3 596 894 1192
Hay shed: l 6 11 17 22
w 10 10 10 10
h 5 5 5 5
m 3 275 550 825 1100
2.5 SUPPORT FUNCTIONS AND PHYSICAL
Manure storage: l
STRUCTURES 9
...........................................................................
17 17 23
13
2.6 TYPICAL FARM L AYOUT AND
(with storage capacity 0.5 year) FENCING
w ..............................................................................................
10 10 15 15 15
h
CHAPTER 3: CATTLE BARN MODULAR 2.5
APPROACH2.5 2.5 2.5 ............................ 16
AND OPERATIONS
m3 225 425 638 863
3.1
Farm M FARMand
ODULAR store
machinery DEVELOPMENT
workshop: ........................................................................................................
l 10 10 20 20 16
3.2 MANAGEMENT OF MODULAR FARM w D EVELOPMENT 10 P LAN
10 ..............................................................
10 10 17
3.2.1. Capacity of the Milking Parlour h .............................................................................................
4.0 4.0 4.0 4.0 17
3.2.2. Manure
Agriculture store: Storage/Waste Water
l Storage 5...................................................................................
5 10 10 18
3.2.3. Waiting Area
(seeds/fertiliser/chemicals) (Holding Pen)w ..................................................................................................
8 8 8 8 19
3.2.4. Treatment/Handling of Cows h .................................................................................................
4 4 4 4.0 19
Feed 3.2.5. Milk
storage and Storagearea:
handling ...........................................................................................................................
l 7.5 7.5 15 15 19
3.2.6.
(concentrates) Cows: Milk Production and w Dimensions 10.0 ...............................................................................
10.0 10.0 10 20
h 4.0 4.0 4.0 4.0 21
1: The 3.2.9. Water
face of the Supply
silage ..........................................................................................................................
should move forward with a minimum speed of 2 meters per week. 21
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester ....................................................................................................................... 35
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CONTENTS
CHAPTER 5: PLANNING AND IMPLEMENTATION
Setting-up a new - or expanding an existing - dairy farm is a heavy investment, not only as regards
LIST
to theOFcowTABLES
house and.........................................................................................................................................
the herd, but also in connection to the support functions referred to in the 03
former chapters. Timely
ABBREVIATIONS planning and a well-considered step-by-step approach are therefore
....................................................................................................................................... 04
critical to avoid mistakes and failure. For example production of fodder needs to start one year
PREAMBLE
before the new................................................................................................................................................
stock arrives. 05
Especially
CHAPTERin 1: dairy farming long ..............................................................................................................
INTRODUCTION term planning is essential. Typically it takes three (3) years 07 of
planning and preparation before a calf starts to produce its first milk! Where a new dairy farm is to
be established, it is recommended that a comprehensive planning cycle is made and followed. This
2.1 ACCESS
planning cycleTO PUBLIC
has 5 steps UTILITIES
or phases: ............................................................................................................... 08
2.3 Concept
a) DAIRY C OW HOUSE DESIGN ................................................................................................................ 10
plan
2.4 Business
b) EXAMPLE LAYOUTand
planning MODULARfeasibility
OF financial DAIRY COW HOUSE ...................................................................... 12
2.5 Preparation
c) SUPPORT Fand planning
UNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13
2.6 Implementation
d) TYPICAL FARM (construction)
LAYOUT AND FENCING .............................................................................................. 15
e) Training and management.
3.1theM
In concept FARMthe
ODULARstage, DEVELOPMENT
project idea........................................................................................................
is borne and appraised as a viable and interesting business 16
3.2 M M F D P ..............................................................
opportunity – pending validation of assumptions as regards to investments, costs and turnover.
Thereafter a business plan is prepared. WaterParticularly
Storage...................................................................................
this plan gives detailed information on the 18
level of required investments, operational costs, sales and incomes, and the expected profit margin 19
3.2.4.
or IRR. Treatment/Handling of Cows ................................................................................................. 19
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.6. Cows:
Once the project is Milk Production
sanctioned by and the Dimensions
owner, the...............................................................................
building plans and time schedules, bills 20 of
quantities, contracts with contractors and suppliers are prepared, and the licenses and permits are 21
3.2.8.
acquired. Grouping of Young Stock ....................................................................................................... 21
3.2.9. Water Supply.......................................................................................................................... 21
The implementation stage is the beginning of the actual construction (ground breaking ceremony).
During this phase – or even before - timely attention must be given to ensure that sufficient feed is
grown, key staff is trained/employed and other support functions are in place.
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
Although the complexities concerned with building a 20 cow modular cow house and a 80 cow
module are quite different, the principles and the importance of a well-planned phased approach,
3.4.3. Week-planning........................................................................................................................ 28
remain basically the same.
5.1 Concept
CHAPTER Plan CALCULATIONS FOR THE MODULAR BARN DESIGN .......................... 34
4: COST
4.1 this
At COW HOUSE
stage, andCin
ONSTRUCTION
order to make COSTS some..................................................................................................
fundamental decisions about the projected business 34
4.1.1. in Construction
enterprise Costs
relation to its Cow scope
scale, House Modules
and products, 1-4 ........................................................................
the project owner must obtain good 34
knowledge and understanding of the local dairy industry. Some fundamental issues that need 35
4.1.2. Biogas Digester ....................................................................................................................... to
4.2considered
be HERD DEVELOPMENT
and decided...........................................................................................................................
upon before preparing the farm business plan may include: 35
4.3 The
MILK PRODUCTION
market andM
dynamicsAND ILK STORAGE ........................................................................................... 36
trend as regards to the demand and sales of raw and processed milk
4.4 (buyers,
FEED AND FEED STORAGE REQUIREMENTS ......................................................................................... 37
price, government policy).
 The potential and profitability of processing raw milk on the farm (cheese, yoghurt).
 Whether the dairy farm shall produce its own fodder (ref. land requirement, investments in
farm machinery, stores).
Page 1
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CONTENTS
 Whether there exists a lucrative or potential market for fattened bull calves (cow house
design)?
 To keep female young stock – next to herd replacement – for rearing and breeding pregnant
heifers.
LIST OF TABLES ......................................................................................................................................... 03
In addition, attention
ABBREVIATIONS must be given to many other practical issues, ranging from the outlook of the
....................................................................................................................................... 04
dairy industry and government policies, access to public utilities, the location of the farm and the
PREAMBLE
siting ................................................................................................................................................
of the cow house and other buildings, the preferred breed of dairy cattle, the amount of land 05
needed
CHAPTER for fodder production, and
1: INTRODUCTION so on and so forth. A brief description is given below of some
.............................................................................................................. 07
of the main areas of concern.
a.
2.1 Dairy sector
ACCESS TO landscape and government
PUBLIC UTILITIES policies
............................................................................................................... 08
2.2 InDorder
AIRY FtoARMprepare
LAY-OUTa good business
PRINCIPLES plan, an overview must be obtained about the national
..................................................................................................... 09
2.3 landscape
DAIRY COW of the
HOUSEdairy industry
DESIGN (demand, prices, processors and other buyers, etc.) and the
................................................................................................................ 10
2.4 national
EXAMPLE policies
LAYOUTin place.
OF MODULARThe latter DAIRYis important
COW HOUSE e.g.......................................................................
as regards to the regulations on the sales 12
2.5 of Sraw milk,
UPPORT prevailingAND
FUNCTIONS tax Pincentives
HYSICAL Ssuch TRUCTURES as exemptions on dairy and farm equipment, and
........................................................................... 13
2.6 VAT policies.
TYPICAL FARM InLaddition
AYOUT AND government may have – or is developing – hygiene and animal
FENCING .............................................................................................. 15
welfare standards for commercial dairy farms, and investors are likely to acquire permits and
building licenses.
3.2 MANAGEMENT
b. Roads, electricityOF Mwater
and ODULAR FARM DEVELOPMENT PLAN .............................................................. 17
The3.2.1. Capacity
farm needs to of the Milking
have easy access Parlour to .............................................................................................
all-weather roads, (preferably 3 phase) electricity and 17
3.2.2.
clean water. Manure Storage/Waste
Long distances and Water
travelStorage
times have ...................................................................................
much impact on the operational costs of the 18
farming enterprise and the quality of milk delivered to the market. 19
3.2.5.
c. Water drainage Milk Storage ........................................................................................................................... 19
3.2.6.
To have good Cows:drainage
Milk Production
on the and farmDimensions
attention ...............................................................................
must be given to sufficient slope in order 20 to
properly discharge excess rain water. A slightly sloped landscape also facilitates the handling 21
of 3.2.8.
manure,Grouping of Younggravity
which requires Stock .......................................................................................................
to transport it from collection gutters to a holding area 21
3.2.9. Water Supply ..........................................................................................................................
(and/or bio-gas processing). For this reason the stables are preferably positioned at the highest 21
3.2.10. Essential Points to
point of the projected project site. Consider for each Module ........................................................................ 22
d. Availability of suitable land for dairy farm structures
3.4 FEED FENCE ........................................................................................................................................... 26
In the event an entire new farm needs to be developed and the farming location has yet to be
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
selected, it is most important to consider some critical selection-criteria in order to identify the
most suitable location where farm stables and other farm structures can be established. These
3.4.3. Week-planning........................................................................................................................ 28
are related to access of roads, electricity supply, water (drainage), conducive climatological
conditions such as temperature and rainfall, and the presence of good and abundant arable
land for fodder crop production. Fields for fodder production should be close to the cow stable
CHAPTER
to avoid4:longCOST CALCULATIONS
distances in bringing the FOR THE to
forages MODULAR
the cows (and BARN manure DESIGN on the ..........................
land). If a farm 34
4.1 is C
feeding fresh grass in a cut-and-carry system the grass fields are to be situated immediately
adjacent
4.1.1. to the cow house.
Construction Costs Preserved
Cow House feeds in silage
Modules bunkers and hay barns need to be at arm’s
1-4 ........................................................................ 34
reach to theBiogas
4.1.2. cow house.
Digester ....................................................................................................................... 35
e.
4.3 Preferred breed of theAND
MILK PRODUCTION herdMILK STORAGE ........................................................................................... 36
4.4 AtFthis
EED AND FEED STORAGE Rmust
stage also attention be given.........................................................................................
EQUIREMENTS to the cattle breed that suits the business plan best. 37
4.5 Basic decisions need to be made on whether to select a typical dairy breed, such as Holstein
MANURE PRODUCTION AND STORAGE ............................................................................................... 39
4.6 Friesian or Jersey, or a dual purpose cow (e.g. Fleckvieh). The latter produces
OTHER FARM BUILDINGS AND STORAGES .......................................................................................... 40 less milk
4.7 compared
SUMMARY toFaARM
typical dairy breed,
STRUCTURE but has better
MEASUREMENTS milk-meat value ratio. The choice of breed
................................................................................. 41
also has implications to the design of the stables, as each breed requires different stable
measurements and size of cubicles.
Page 1
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CONTENTS
f. Size of land in relation to feed/forage requirements

With regards to the required amount of land some basic decisions need to be made, depending
first of all on the availability of dairy feed and whether land is needed to cultivate forages.
LISTTheOFcost
TABLESof feed.........................................................................................................................................
may be as high as 60-65% of the total cost price of milk. It is therefore 03
important to understand
ABBREVIATIONS the cost drivers of feed and ideally the production of forages on-the-
....................................................................................................................................... 04
farm is part of the business plan. Although the investment is considerable - in land, machinery,
manpower ................................................................................................................................................
PREAMBLE – it is the best guarantee to secure sufficient and timely supply at affordable prices 05
or costs.1:Supply
CHAPTER of forages by ..............................................................................................................
INTRODUCTION third parties, may be considered, although it exposes the farmer 07
to extra risks and disadvantages- particularly in regard to seasonality in prices, timely supply
of sufficient quantities and quality. CONSIDERATIONS AND IMPLICATIONS ................................. 08
2.2 Sufficient
DAIRY Farea
ARM must
LAY-OUT alsoPbe reserved.....................................................................................................
RINCIPLES for the storage of silage and hay in pits respectively barns. 09
2.3 Other
DAIRYstructures
COW HOUSE to consider if growing forages on-site are the farm machinery shed and an
DESIGN ................................................................................................................ 10
2.4 agricultural
EXAMPLE LinputAYOUTstore OF M(fertiliser,
ODULAR Dseeds, AIRY COW chemicals etc.). With regards to the siting of these
HOUSE ...................................................................... 12
structures on the farm, considerations must be given to security, safety
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 and efficiency. Hay
2.6 stacks or barns
TYPICAL FARMare for example
LAYOUT AND FENCING preferably located at some distance from other structures as15
.............................................................................................. a
result of the risk of fire.
3.1 Planning
MODULAR forFARM
herdDdevelopment
EVELOPMENT ........................................................................................................
and forage production usually go hand in hand, as the 16
3.2 growing
MANAGEMENT OF MODULAR
herd requires more fodder. FARM D Kenya dairyPfarming
InEVELOPMENT LAN ..............................................................
is rain-fed with usually one long 17
and one short
3.2.1. rainyofseason,
Capacity the Milking of which
Parlour it .............................................................................................
is not uncommon that one fails. This requires forward 17
3.2.2. and
planning Manure
largeStorage/Waste
storage capacity Water of Storage
forages, ...................................................................................
notably maize silage that can cover a period 18 of
at least 18 months. For this reason it is also advisable to include extra land in the initial 19
3.2.4. planning,
business Treatment/Handling
which enables of Cows .................................................................................................
expansion of forage crop production, next to the land space 19
3.2.5. Milk Storage ...........................................................................................................................
required for expansion of stables and utilities (NB: as a simple guideline a herd of 20 cows and 19
young stock needs approximately 40 acres of land for fodder maize for silage to cover a period 20
3.2.7.
of 18 months).Special Needs Cows ................................................................................................................ 21
3.2.9.
g. Time planning Water Supply.......................................................................................................................... 21
3.2.10. Essential Points
It is recommended that a to timeConsider
schedule for each Module
or plan ........................................................................
is prepared as part of the concept stage. The 22
3.2.11.
time Management
schedule addressestothe Increase
majorNumbertimelines of Cows .............................................................................
as regards to actions to be taken and deliverables. 22
3.3 Briefly
DESIGN OF FLOORS AND CUBICLES ..................................................................................................... 23
these can be categorised as follows:
3.4 FEED FENCE ........................................................................................................................................... 26
 Planning and preparation (hardware supply, contracts, permits and licenses etc.)
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
 Construction
 Cultivation of forages (harvested and stored before the arrival of cattle)
3.4.3. Week-planning........................................................................................................................ 28
Sourcing
3.5  HYGIENE of cattle
AND BIOSECURITY ................................................................................................................ 29
 Training/employing
3.6 TREATMENT AND HANDLING farm D manager/workers
AIRY CATTLE .................................................................................... 32
 Start farming operations.
4.1 Although
COW HOUSE this Handbook
CONSTRUCTION providesCOSTSexhaustive information about the stable design, it is never-
.................................................................................................. 34
theless
4.1.1. advisable to involve an architect in the preparation and planning phase
Construction Costs Cow House Modules 1-4 ........................................................................ 34of the project.
An4.1.2.
architect mayDigester
Biogas assist in obtaining permits and licenses and could provide other services
....................................................................................................................... 35
4.2 during
HERDthe construction...........................................................................................................................
DEVELOPMENT (including supervision). The architect – possibly in consultation with35a
4.3 dairy
MILK consultant
PRODUCTION - willAND
alsoMbe ILKable to advice
STORAGE as regards to any diversions from the plan.
........................................................................................... 36
4.5 Well in advance
MANURE of the arrival
PRODUCTION AND Sof cattle, ...............................................................................................
TORAGE feed sources and supply must be organised. Reliance on 39
4.6 on-farm
OTHER F forage production
ARM BUILDINGS AND requires
STORAGES planning at least one year ahead in terms of land
.......................................................................................... 40
4.7 preparation,
SUMMARY Fcultivation,
ARM STRUCTURE harvesting and fodder.................................................................................
MEASUREMENTS preservation. Ideally the feed storage facilities 41
are fully stacked at the moment cattle arrive at the farm.
Page 1
Page 44
page | 44
CONTENTS
The arrival of cattle is a critical deadline in the project planning and therefore, a major
reference point to the whole project planning. In this regard also possible quarantine periods
and/or veterinary health requirements need consideration (transportation of livestock).
LIST OF TABLES ......................................................................................................................................... 03

5.2 Business Planning and Financial Feasibility
ABBREVIATIONS ....................................................................................................................................... 04
Once the concept
PREAMBLE plan is accepted and validated, a business plan is developed. The business plan
................................................................................................................................................ 05
shows the financial or commercial feasibility of the proposed project. Irrespective of the project
size, the business plan should include a description of the business operations, the required
investments,
CHAPTER 2:the operational costs
STRUCTURES, including salaries and
CONSIDERATIONS AND staff qualifications, sales
IMPLICATIONS & incomes and08
................................. a
timeline.
If so required or desired, the business plan could be divided in two parts: one business plan for
only the dairy farming operations and one business plan for forage production. In this case the
dairy unit would purchase fodder from the forage unit at market conform prices/costs.
The financial section of the business plan includes a balance sheet. The business plan may be
essential in case external funding is required in order to finance the project (e.g. banks, investors).
CHAPTER
In 3: it
such cases CATTLE
is recommendedBARN MODULAR that the business APPROACH plan gets ANDpreparedOPERATIONS in a bankable............................
format. As 16
regards to the financial
3.1 MODULAR FARM Dparagraph of the business plan the major topics to be addressed are listed
EVELOPMENT ........................................................................................................ 16
below:
a. Initial investments
 Land cost (if
3.2.3. hired it
Waiting is an
Area operational
(Holding cost)
Pen) .................................................................................................. 19
 Livestock
3.2.4. purchases
 Construction
3.2.5. Milkcosts of physical
Storage structures (including design costs, permit fees etc.)
........................................................................................................................... 19
 Other3.2.6.hardware
Cows: such
Milk as equipment,
Production and machinery, implements, furniture, tools etc.
Dimensions ............................................................................... 20
 Public utilities (water, roads, electricity connection or generator)
3.2.9. costs
b. Operating Water Supply.......................................................................................................................... 21
 Land lease Essential Points to Consider for each Module ........................................................................ 22
3.2.10.
3.2.11.and
 Salaries Management
wages to Increase Number of Cows............................................................................. 22
3.3 D ESIGN
 Feed costs OF F LOORS AND CUBICLES ..................................................................................................... 23
3.4 FEED FENCE
 Machinery ...........................................................................................................................................
consumables (fuel) and insurances 26
3.4.1. Breeding Bull(s)
 Machinery repair and maintenance ...................................................................................................................... 26
 Operating costs per hectare (incl. irrigation)
3.4.3. Week-planning........................................................................................................................ 28
 Consumables, supplies
 Vet/AI (medicines, services)
 Interest paid on loans and insurances
CHAPTER 4: COST CALCULATIONS
 Others (preparation cost etc.). FOR THE MODULAR BARN DESIGN .......................... 34
c. Production
4.1.1. and revenues:Costs Cow House Modules 1-4 ........................................................................ 34
Construction
 Fresh milk
4.1.2. (or processed
Biogas Digesterif any)
....................................................................................................................... 35
4.2 Livestock sales
HERD DEVELOPMENT ........................................................................................................................... 35
 Manure
4.3 MILK Psales
 Forage
4.4 FEED sales
AND FEED STORAGE REQUIREMENTS ......................................................................................... 37
 Others
d. Cash
4.7 flow
SUMMARY FARM STRUCTURE MEASUREMENTS ................................................................................. 41
e. Depreciation
Page 1
Page 45
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CONTENTS
e. Taxes and funding
f. Profit and loss (IRR)

LIST OF TABLES ......................................................................................................................................... 03
g. Design drawings....................................................................................................................................... 04
ABBREVIATIONS
PREAMBLE
In ................................................................................................................................................
order to capture the project construction cost as accurate as possible, design drawings can be 05
done.
CHAPTERAlthough this is at a considerable
1: INTRODUCTION cost, it provides a clearer view of all the costs that are
.............................................................................................................. 07
involved in the project. These drawings are also helpful in understanding the final business plan
CHAPTER
and 2: section,
financial STRUCTURES, which may CONSIDERATIONS
be of particular importance AND IMPLICATIONS
in the event the project .................................
seeks external 08
funding.
Usually
2.3 DAIRY the design
COW HOUSE drawings DESIGN are................................................................................................................
done by an architect, who will also generate a Bill of Quantities 10
(BOQ). The BOQ
2.4 EXAMPLE lists all
LAYOUT OFthe required
MODULAR materials
DAIRY COW needed, including the material specification, the
HOUSE ...................................................................... 12
quantities and a cost indication for each item. The set of drawings and
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 BOQ provide a good
indication
2.6 TYPICAL of the
FARM project
LAYOUT construction
AND FENCING cost..............................................................................................
and is also used in the next planning stage (5.3) 15 as
reference to select the best offer in case the project gets tendered.
This MODULAR Fincludes
3.1 Handbook ARM DEVELOPMENT in Annex 3........................................................................................................
design drawings and the BOQ – including an indicative 16
3.2 MANAGEMENT
pricelist – of the modular OF MODULAR
cow house FARM DEVELOPMENT
design for 20-40-60-80 PLANcows. ..............................................................
The cow house design includes 17
the milking
3.2.1. parlour,
Capacity theofoffice room, Parlour
the Milking the milk annex machine room, an ablution block and dressing
............................................................................................. 17
room 3.2.2.
and the Manure
manure Storage/Waste
pit. For the business Water Storage plan ...................................................................................
of a new dairy farm – or in case replacement 18 or
expansion of other buildings is needed at an existing farm - it is recommended to also have design 19
3.2.4.and BOQs
drawings Treatment/Handling
prepared by the of Cows .................................................................................................
architect. This also applies to the technical drawings for other 19
3.2.5. Milk Storage ...........................................................................................................................
structures, such as the agriculture store, hay and silage storage and the machinery/workshop 19
3.2.6. Cows: Milk Production and Dimensions
shed. In the project site layout these structures are also shown. ............................................................................... 20
5.3 3.2.9.
Preparation Waterand Planning
Supply for Implementation
.......................................................................................................................... 21
In case the business
3.2.11. Management plan showsto Increase thatNumber
the proposed project is feasible from both a financial and
of Cows............................................................................. 22
technical
3.3 DESIGNpointOFof view, AND
FLOORS the project
CUBICLES is ready to start. This phase requires that sufficient funds are
..................................................................................................... 23
made Favailable
3.4 EED FENCE for...........................................................................................................................................
the purchase of building materials, equipment/machinery and dairy cows, and 26
payment
3.4.1.of the contractor
Breeding and other advisors. There is need to prepare and plan for
Bull(s) ...................................................................................................................... 26
implementation
3.4.2. very well
Schedule for BarnandInspection
numerous activities
Rounds need to be addressed during this planning
.................................................................................... 27
stage.3.4.3.
These may vary from one
Week-planning project to another and therefore below only the main activities are
........................................................................................................................ 28
3.5 HYGIENE
summarised. They
ANDcan BIOSECURITY
be grouped ................................................................................................................
as follows: 29
a) Construction-related
CHAPTER 4: COST CALCULATIONS activities FOR THE MODULAR BARN DESIGN .......................... 34
b) Procurement of equipment, machinery and livestock
4.1 COW HOUSE
c) Contractual CONSTRUCTION
arrangements (e.g.Cdispatch
OSTS ..................................................................................................
of fresh milk and supply of feed) 34
4.1.2.
a.1) Construction Biogas
works Digester ....................................................................................................................... 35
4.2 H
Regarding the preparation...........................................................................................................................
ERD D EVELOPMENT of the construction works, it is recommended to engage an architect 35
4.3 aMproven
with ILK PRODUCTION
track record AND in M ILK STORAGE
agriculture ...........................................................................................
related projects. Experience in this field is required so 36 as
4.4 F
to have full understanding of the specific issues that (may) arise in an agricultural project, such 37
EED AND FEED S TORAGE R EQUIREMENTS ......................................................................................... as
4.5 comfort
cow MANURE andPRODUCTION
animal health AND STORAGE
related ............................................................................................... 39
issues.
4.6 architect
The OTHER Fwill BUILDINGS
ARMprepare the ANDdesign STORAGES
drawings, ..........................................................................................
the BOQ with a price list and a site plan. He may 40
4.7 S
also be asked to arrange for tendering of the project usually this is done by asking for a proposal 41
UMMARY F ARM S TRUCTURE M EASUREMENTS ................................................................................. or
quotation from a minimum of 3 contractors. As for the site plan, the optimal location of the
structures is determined by the straight line concept and other principles referred to Page
under1
Page 46
page | 46
CONTENTS
Chapter 2.2. However the landscape on-site, the available space and the presence of existing
buildings may cause need to divert from these principles. Special attention may go to:
 Manure handling- and storagearea
 Storage area of silage and hay,
LIST OF TABLES
 Dairy .........................................................................................................................................
feed handling- and storage area, 03
 Utility buildings,.......................................................................................................................................
ABBREVIATIONS such as the agriculture store. 04
PREAMBLE ................................................................................................................................................ 05
a.2) Arranging the required licences and permits
The architects
CHAPTER may also provide additional
1: INTRODUCTION services to facilitate the project, such as dealing with
.............................................................................................................. 07
local authorities in order to ensure the project objectives are made in accordance to law and
regulations in force, such as:
2.1 Spatial
ACCESS TO PUBLIC
planning andUzoning ...............................................................................................................
TILITIES(rural/urban planning) 08
2.2 D AIRY FARM LAY - OUT P RINCIPLES
 Construction permit (County Government) ..................................................................................................... 09
2.3 DAIRY COW Hlicense
 Environmental OUSE DorESIGN
permit ................................................................................................................
(EIA/NEMA) 10
2.4 E XAMPLE LAYOUT OF M ODULAR D AIRY C OW
 Connection to national grids for electricity and piped-water supplyH OUSE ...................................................................... 12
2.5 SUPPORT
 Permits for FaUNCTIONS
deep-well,AND PHYSICAL
borehole, damSTRUCTURES
and use of surface ...........................................................................
water (water permits). 13
2.6 T YPICAL F ARM LAYOUT AND F ENCING ..............................................................................................
 Permits to import cattle (if applicable) from DVS/State Department of Livestock 15
 Others regulatory
CHAPTER 3: CATTLE standards
BARN MODULAR APPROACH AND OPERATIONS ............................ 16
In Kenya, an Environmental Impact Analysis is administered by The National Environment
Management Authority (NEMA) as per Environmental Management and Coordination Act
(EMCA) (1999) and the Environmental Impact Assessment and Audit Regulations (2003).
Reference is made to Annex 7 for more detailed information concerning government regulations in
relation to building construction projects.
3.2.5. Milk Storage ........................................................................................................................... 19
a.3) Supervision
3.2.6. of the
Cows: construction
Milk Productionactivities
and Dimensions ............................................................................... 20
In the3.2.7.
event the
Special Needs supervises
architect the construction works (which is recommended!), he can
Cows ................................................................................................................ 21
review3.2.8.
the contractor’s shop drawings and other submittals, prepare and issue site inspections
Grouping of Young Stock ....................................................................................................... 21 and
instructions,
3.2.9. and provide
Water Supplyconstruction contract administration and certificates for payment.
.......................................................................................................................... 21
b) Procurement of equipment,
3.2.11. Management machinery
to Increase Number andoflivestock
Cows............................................................................. 22
The hardware that needs to be procured is listed in the business plan and the BOQ. Careful
attention must be given to the planning and timing of the procurement of machinery and
3.4 FEED FENCE ........................................................................................................................................... 26
equipment,
3.4.1. as Breeding
some need to be
Bull(s) installed during the construction works. Equally important is the
...................................................................................................................... 26
moment of procuring
3.4.2. Schedule livestock, which can
for Barn Inspection Roundsonly....................................................................................
arrive at the farm when construction works are 27
completed,
3.4.3. enough clean water, feed and forages are available, and a trained workforce is present.
Week-planning........................................................................................................................ 28
Although
3.5 HYGIENE most AND
is straight forward
BIOSECURITY there are a few priorities in the procurement process, which are:
................................................................................................................ 29
 Procure
3.6 agricultural
TREATMENT AND Hequipment
ANDLING Dfirst AIRY(land
CATTLE preparation, irrigation, planting, harvesting)
.................................................................................... 32
 Pay attention to equipment that needs to be imported because of longed delivery times
 Pay special attention to equipment that needs to be installed during the construction works
COW Hparlour,
4.1 (milking OUSE CONSTRUCTION
milk cooling C OSTS ..................................................................................................
equipment, stable interior and the like) 34
In the4.1.2. Biogas
event dairy Digester
cattle will .......................................................................................................................
have to be procured from outside the local proximity, attention must 35
4.2 H ERD D EVELOPMENT ...........................................................................................................................
be given to veterinary protocols e.g. vaccinations, quarantine period and transportation 35
regulations.
4.5 MANUREarrangements
c) Contractual PRODUCTION AND STORAGE ............................................................................................... 39
4.6order
In OTHER FARMthe
to secure BUILDINGS
dispatchAND andSTORAGES
sales of farm ..........................................................................................
products (fresh milk) it is advisable to arrange40 a
4.7 SUMMARY FARM S TRUCTURE M EASUREMENTS .................................................................................
contractual agreement with a dairy processor or a dairy cooperative (fresh milk delivery contract). 41
Of similar importance is the security of reliable supply of dairy feed, such as dairy concentrates
and ground materials. Page 1
Page 47
page | 47
CONTENTS
5.4 Implementation of Construction Works
The implementation stage normally starts with a ground breaking ceremony. As emphasised in the
previous chapter, important during the implementation stage are (a) the involvement of the
architect
LIST OF for supervision
TABLES of the works, and (b) the procurement of hardware.
......................................................................................................................................... 03
The project manager/owner needs to be alert that equipment that requires specific testing (such as
ABBREVIATIONS ....................................................................................................................................... 04
milking parlour equipment, milk cooling equipment, irrigation installations), is tested directly
PREAMBLE ................................................................................................................................................
after installation. This kind of equipment needs certificates that state and validate performance 05 in
accordance with the technical specifications and warrantees from the manufacturer.
CHAPTER 1: INTRODUCTION .............................................................................................................. 07 It usually
involves preparation and submittal of test reports by a qualified and accredited technician, stating
the testing procedures, CONSIDERATIONS
the performance standards andAND the testIMPLICATIONS
results. ................................. 08
Concerning
2.2 DAIRY theFARMconstruction
LAY-OUT Pworks it is.....................................................................................................
RINCIPLES advisable that the architect issues certificates of completion 09
for each phase of the work, and for completion of the works. These will state that the construction
works have been
2.4 EXAMPLE completed
LAYOUT in accordance
OF MODULAR DAIRY COW with HOUSEthe ......................................................................
terms and conditions laid down in the 12
construction contract (and e.g. in the tender documents) and according to professional
2.5 SUPPORT FUNCTIONS AND PHYSICAL STRUCTURES ........................................................................... 13 standards.
The
2.6 certificates
TYPICAL FARMare Lused
AYOUT toAND
approve
FENCING and release payments to the contractor for the phase
.............................................................................................. 15
completed.
5.5
3.2 Farm
M Management and Training
ANAGEMENT OF MODULAR FARM DEVELOPMENT PLAN .............................................................. 17
Depending on the ability and availability of the farm owner/investor to take lead in farm
operations,
3.2.3. theWaiting
farm workers and the
Area (Holding Pen)manager (if present/required) require the proper skills and
.................................................................................................. 19
knowledge
3.2.4. to manage the farm efficiently and effectively.
In case of a new
3.2.5. Milkdairy farm
Storage enterprise, every worker should either have proven experience 19
........................................................................................................................... or
received adequate
3.2.6. training in the specific field of operations. One of the key issues
Cows: Milk Production and Dimensions ............................................................................... 20 in farm
management
3.2.7. is herdNeeds
Special management, which includes feeding, herd health and fertility, milk
Cows ................................................................................................................ 21
production
3.2.8. and rearing. Nowadays computerised dairy herd management and/or farm recording
programmes
3.2.9. exist
Water and may..........................................................................................................................
Supply be considered to be included in the farm plan. In addition it is advised 21
to organise
3.2.10. for sufficient
Essential Pointsconsultancy/training
to Consider for each Module and support services (Vet/AI services, fodder
........................................................................ 22
production, bookkeeping) to backstop the farm manager/owner and his staff.
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s) ...................................................................................................................... 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester ....................................................................................................................... 35
Page 1
Page 48
page | 48
CONTENTS
LIST OF TABLES .........................................................................................................................................03

ABBREVIATIONS .......................................................................................................................................04
PREAMBLE ................................................................................................................................................05
3.2.5. Milk Storage ........................................................................................................................... 19
3.2.6. Cows: Milk Production and Dimensions Kenya...............................................................................
Market-led Dairy Program is funded by: 20
The Embassy of the Kingdom of the Netherlands 21
3.2.8. Nairobi, Kenya
3.2.9. Water Supply.......................................................................................................................... 21
3.4 FEED FENCE ........................................................................................................................................... 26
3.4.1. Breeding Bull(s)...................................................................................................................... 26
3.4.3. Week-planning........................................................................................................................ 28
4.1.2. Biogas Digester....................................................................................................................... 35
SNV Netherlands Development Organisation - Kenya
Ngong Lane, off Ngong Road
4.6 OTHER FARM BUILDINGS AND STORAGES P.O. Box ..........................................................................................
30776 - 00100 40
4.7 SUMMARY FARM STRUCTURE MEASUREMENTS Nairobi, Kenya................................................................................. 41
T + 254 20 3873656
F + 254 20 3873650
E kenya@snvworld.org Page 1
www.snvworld.org
page | 113

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Handbook: Designing and Planning Modular Dairy Cow House (Kenya) www.modulardairyfarm.

LIST OF TABLES ......................................................................................................................................... 03

LIST OF TABLES ......................................................................................................................................... 03

This Handbook presents an investment plan(s) and technical drawings (including a 3D

Figure 2. Barn layout (top view 40 cows module)

LIST OF TABLES ......................................................................................................................................... 03

More information on floor design and construction is presented in Annex 1.

LIST OF TABLES .........................................................................................................................................03

Table 6. Barn inspection round schedule

CHAPTER 3: CATTLE BARN  Check all cows for

LIST OF TABLES ......................................................................................................................................... 03

The following activities can be organized in a free-stall at the different sections/locations:

LIST OF TABLES ......................................................................................................................................... 03

f. Size of land in relation to feed/forage requirements

LIST OF TABLES ......................................................................................................................................... 03

e. Taxes and funding

f. Profit and loss (IRR)

LIST OF TABLES .........................................................................................................................................03

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