How Robotic Milking Transformed an Upland Dairy Farm

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Bromfield Farm, located near Wigton in Cumbria, has embraced advanced technology with the installation of seven robotic milking systems and two robotic feed pushers. This shift has significantly reduced labor demands while improving both cow health and milk production across their 315-cow dairy operation.

Recognizing the need to replace their outdated herringbone milking parlour, second-generation farmer Harold Armstrong, alongside his sons David and Andrew, began exploring more efficient alternatives. Their interest in robotics was initially piqued by the availability of capital grants supporting such investments. They opted for a hybrid approach, integrating a free-access milking system with a guided exit and a fully guided system.

Farm at a Glance:

Herd size: 315 cows
Land area: 263ha (owned and rented)
Milk yield: 10,690 litres per cow at 4.5% butterfat and 3.4% protein
Calving: Year-round
Housing: Milkers kept indoors; dry cows graze during summer
Foot health: Hoofcount automatic foot-baths help control digital dermatitis

Investment in Robotics

In 2019, the Armstrongs installed four GEA R9500 free-access robots with guided exits in two existing sheds, supplied and fitted by GD&M Dunglinson of Carlisle. Encouraged by the success of this system, they expanded further in 2024, constructing a new 150-stall cubicle house equipped with three second-hand, fully guided GEA R9500 robots.

The investment, amounting to £2,000 per cow place, covered the costs of the new building, seven milking robots, and two robotic feed pushers. The Armstrong family considers this one of their best decisions to date, given the numerous benefits it has delivered.

Key Benefits

Since adopting robotic milking, Bromfield Farm has increased cow numbers by 43%, with scope for further expansion. Additional benefits include:

Milk yield: Increased from 30 to 35 litres per cow per day
Mastitis cases: Reduced from 45% (100 cases in 220 cows) to 22% (70 cases in 315 cows)
Somatic cell count: Decreased from 120,000 to 90,000 cells/ml
Bactoscan readings: Improved from 28 to 17 units
Lameness rate: Maintained at 17%
Antibiotic use: Expected reduction due to fewer mastitis cases

David attributes these improvements to the detailed individual cow data collected by the milking robots and GEA Cow Scout collars. “Before the robots, we had no individualized data. Now, we can proactively address issues, which has significantly improved herd health,” he explains.

The robots also enhance milk quality by monitoring conductivity in each udder quarter, supporting selective dry cow therapy in compliance with Arla’s milk processor requirements. Additionally, targeted milking features minimize milk wastage, further improving efficiency.

Advanced Robotic Features

The farm's robotic milking system incorporates several key innovations:

In-Liner Everything Technology: Performs stimulation, teat cleaning, milking, and post-dipping in a single teat cup, ensuring efficient milking and hygiene.
Compact design: The 5.3sq m robot features a quiet, electrically driven arm, making it ideal for heifers.
Adjustable box size: Automatically adapts to each cow, ensuring consistent udder positioning for efficient milking.
3D Time-of-Flight Camera: Improves teat detection accuracy and reliability.
Enhanced cow flow: Side entry and exit gates optimize movement and reduce bottlenecks.
Manual cluster attachment: A useful feature for safely training heifers and handling special cases.

Fully Guided vs. Free-Access Systems

In their latest expansion, the Armstrongs introduced a fully guided milking system using a “milk-first” configuration. Cows must pass through a selection gate before reaching the feed barrier; those eligible for milking are directed to the holding area first.

David highlights its labor-saving advantages: “Late-lactation cows tend to become lazy, but this system encourages movement as they still want to eat. It also ensures optimal robot utilization by preventing false visits.”

The guided system also facilitates better body condition management, particularly for cows over 250 days in milk. Currently, late-lactation cows average 2.49 milkings per day, yielding 28.8 litres, while those in the free-access system milk 2.87 times daily, yielding 37.29 litres.

Meanwhile, the free-access system allows cows to voluntarily enter the milking robot. If they are not yet due for milking, they are directed back to the cubicle shed. This setup also features guided exits, enabling easy segregation of cows for health checks or treatments. Two of the robots specifically service heifers, helping maintain their production at 82% of mature cows' yield by minimizing competition and bullying.

Robotic Feed Pushers Boost Efficiency

To further optimize efficiency, two GEA F4800 robotic feed pushers operate in each shed. These devices ensure a constant supply of fresh feed, increasing dry matter intake by 3.5% and reducing bullying at the feed fence. By keeping feed accessible, they also encourage cows to remain active and maintain good production levels.

Choosing the Right System

Simon Harper, sales director at GEA, notes that system selection depends on farm layout and personal preference. “A fully guided system is slightly more expensive due to additional gates and a specific layout requirement. However, when building a new cubicle shed, it is worth considering as it reduces labor requirements.”

Farm Performance Metrics

Average somatic cell count: 90,000 cells/ml milk
Mastitis rate reduction: From 45% to 22%
Milk yield increase: 17% since introducing robotic milking

The Armstrong family’s investment in robotic milking has not only improved efficiency but has also set the farm on a path for future expansion and continued success.