Robotic Milking and Rotary Carousels: Global Trends in Dairy Farming and Prospects for Kazakhstan

Advantages of Rotary Carousels

"There are currently two main trends in dairy farming," said Andrey Morzak. "Those farms that are expanding are moving towards carousels. Those who cannot increase their herd size, for example, due to a lack of labor resources, are transitioning to robotic milking."

The main advantage of the carousel is its efficiency, as the rotary parlor allows for the maximum number of cows to be milked per hour. There is no need to form groups of animals proportional to the number of milking places. The carousel works like a conveyor belt – it is essentially a milk factory. Milking machine operators stay in place, each performing their function as the carousel moves around.

To ensure the carousel operates as efficiently as possible, DeLaval designers have included several options. For example, the carousel can automatically adjust to the milk yield of the animal or group of animals during milking. If the system detects that the cows are being milked quickly, it can accelerate rotation, allowing more animals to be milked per hour.

"One of the main advantages of the carousel is that its throughput does not decrease with an increase in herd size, unlike with parallel or herringbone parlors," noted Andrey Morzak. "So, if a 40-place carousel makes five to six rotations per hour, an 80-place carousel will also make five to six rotations. Meanwhile, in parallel and herringbone parlors, the number of animals milked per hour decreases as the number of milking places in the parlor increases. This is one of the key reasons why large milk producers are now choosing carousels."

Comfort for People and Cows

"Farmers often worry before launching a carousel for the first time," said the DeLaval manager. "They have always milked with ties or in parallel parlors and do not know how the cows will behave on the carousel. In most cases, people are more afraid than the animals. Cows adapt to the carousel very quickly, within one or two milkings. If we use a carousel with an external operator position, the cows can see each other, which creates a sense of calm and comfort."

For the operators, the comfort lies in not having to walk; the cows come to them. The milker has everything they need for work at hand. The equipment has voice and visual alerts that inform operators if any problems arise, such as the drop-off of a milking unit, a milking ban issued by a veterinarian, or if a cow finishes milking earlier than expected. The operator can immediately make decisions based on the necessary actions for the situation.

Modern devices are increasingly moving towards automation. For example, upon customer request, a robot can be installed on the carousel to treat teats after milking.

Operators can also observe the entry and exit of animals and manage them using an automatic pusher from their workstation.

Many solutions are developed based on farmers' feedback. For instance, DeLaval has designed special trays at the entry/exit of the carousel to protect operators from urine or manure. Cows rarely defecate in the milking parlor, but this can happen in stressful situations for the animal.

"There are no minor details on the farm, and every seemingly insignificant nuance affects the overall operation," noted Andrey Morzak. "In DeLaval carousels, the entry and exit for cows are designed to allow animals to move comfortably without creating congestion. The 15-degree angle on the carousel makes it easier for cows to exit by taking a step or two backward first, facilitated by a special bar. The optimal width of the entry, one and a half cows, prevents bottlenecks at the platform entry, significantly enhancing the carousel's efficiency. If one cow slows down, the next one can pass onto the carousel without issue."

Optimal Choice

When choosing a milking system, the expert recommends considering several factors: the number of dairy cows, the maximum number of milkings per day, the total duration of milking, and more. The availability of labor resources in the farm's location is also crucial, not just for the present but for the future. The productivity of any farm depends on its workforce.

Even though milking machine operators do not need to move much at work, the job still requires a certain level of endurance. Therefore, in European countries and the USA, young and middle-aged individuals are preferred for this role.

"No matter how technologically advanced the chosen solution is, operators can slow down its operation if they cannot keep up with their duties," explained Andrey Morzak. "This raises the question of investment returns. The cost of a carousel is higher than other types of milking parlors, and the investor must clearly understand whether the expected return will be achieved."

If calculations favor the carousel, the investor benefits from higher productivity of milking operators. Compared to working in a parallel parlor, the efficiency of milking machine operators is almost 1.5 times higher.

Plans in Kazakhstan

DeLaval is actively developing its business in Kazakhstan, increasing its staff. According to Andrey Morzak, the primary business strategy focuses on quality development. Installing equipment means that dairy farms/farmers receive support during the launch and training of employees in working with the technology. DeLaval specialists provide support throughout the equipment's life, understanding that staff can change over time.

Additionally, modern technologies for milking, animal housing, and other processes on dairy farms are being actively implemented in Kazakhstan, and DeLaval has much to offer.

One of the company's projects is the installation of the E300 carousel model with 80 places at the Rodina Agrofirm. This is one of DeLaval's latest developments, with speed being its main advantage.

"Our company's concept is to provide large dairy farms with industrial solutions that meet their needs. A 400-head farm and a thousand-head farm are two different enterprises, and their equipment needs are different. All key components that affect equipment operation are duplicated, and each detail is designed to ensure the equipment operates 24 hours a day, 365 days a year. Our carousels have separate clean and dirty zones. All electronic equipment is inside the platform to protect it from dirt and moisture, extending its lifespan. The platform and components are designed so that in case of emergencies, such as a power surge, the service team can fix the issue without stopping the carousel. Components can be replaced if necessary without halting operations. Therefore, we are always ready to offer industrial dairy farms solutions that meet their project needs," concluded Andrey Morzak.