Our Final Project for 2011...the BIG Project!

Well, our hoop jumping and waiting are over!  Last week on Monday we received word that we had been approved by the Small Business Administration (SBA) for our loan for our final project for 2011, the BIG project...our new barn!!!!  Before I start posting video and pictures from the construction, I thought I had better start at the beginning with the plan and the reasons why we are building a new barn. 
Below you can see a picture of our cows resting comfortably in our current barn.  We built that barn in 2005, and have been generally pleased with how our cows are doing in there, but we know they deserve better.  This barn is a bedded pack barn, which is a "one size fits all" type of a barn.  Our cows had an enormous amount of flexibility to move around where they would want, but with that flexibility came some challenges.  They were at risk of stepping on each other, laying in manure (causing them to get infections and just be dirty) and at risk of getting infections in their feet.  All of these challenges were manageable, but we knew we could do better.  The cows are comfortable, and that's hard to beat.....meet the new barn!

Our new barn will be a free stall barn, which will allow us to have designated areas (beds) for each cow, preventing them from laying in manure, stepping on each other, and fighting for their favorite spot.  These beds will be bedded with sand instead of saw dust.  Since sand is inorganic, bacteria have a hard time growing, thereby helping us to maintain quality milk from healthy cows.  The sand also gives traction to the cows walking on concrete.  Mature cows will be in one pen and new heifers/smaller cows will be in another pen.  We are actually not adding cows, contrary to the rumors flying around, but making more space for our growing herd.  The entire milking herd will be moving to the new barn once it's completed.  But have no fear, we are still going to be using our 2005 barn...just with a new purpose....a dry cow/fresh cow/special needs barn! 

For the past 5 years we have been "housing" our dry cows (pregnant cows, right before calving) outdoors, with no shed.  The have shade in the summer and wind breaks in the winter, and that's been working for us, but it takes LOTS of hard work on our part to make sure that these important animals on our farm get the best care possible.  When we move the milking herd out of the 2005 barn we will move the dry cows and pregnant heifers into the pack barn.  We plan on leaving our half of the pack barn as a pack, bedded with dry corn leaves and stalks.  These pens will allows us to have our dry cows indoors!  They will be able to enjoy shelter from the Minnesota weather (mainly the winters that are the hardest!) as well as deliver their calves in more comfortable facility.  In the case that a cow needs help delivering her calf, we will now have facilities that will make that care possible.  I speak from experience, that it's not fun trying to chase a cow that's calving around in a big yard, let alone in a muddy or snowy yard!  It's this part of the project that makes us the most excited!  Giving better care to my pregnant cows makes me so thrilled!  They are tough girls, and handled the outdoors just fine, but on those wet and snowy days, I really felt for them. 

This is a big project, but financially we aren't going to be spending any more per month than we are now.  So how's that work???  Well, when we built our pack barn in 2005 the cost of saw dust was less than 50% than what it is now.  Currently we spend enough each month on saw dust bedding for the pack barn, that we have enough money to cover the loan payments and the cost of sand bedding!  We are confident these changes will help us to increase the quality of care that our cows get each day, and to us, that means more than any financial benefit.  Peace of mind, knowing our cows rest safely in a new barn, clean & comfortable....is priceless!!!

Our cows resting comfortably in our current barn,
 but we hope they'll be even more comfortable
in the new barn!

The PLAN...including the next steps for the Spring 2012.

Saturated & Muddy!

Saturated & Muddy!  That's how I would describe the "environment" on Orange Patch Dairy, these days.  There are so many things to be done on the farm, but there's literally too much mud, rain, slop, and muck to get it done.  I would take pictures to share our misery, but it's almost embarrassing.  Just when the weather clears, and the soil finally starts to dry, and it might look like we can get back in the fields (we have corn to finish planting, soybeans to start, and alfalfa to chop) we receive another 1/2 to 1 inch of rain.  This morning we were "blessed" with another 1+ inch of rain.  The forecast has more rain predicted for tonight as well as Thursday night.  The sun might actually come out this weekend, but that's just in time for my brother in law's graduation party....which means we can't be in the field. 

Then there's the cows.  It's so muddy in the cow yards right now, it has become impossible to get bedding to the cows.  Thankfully the sand corners of the pens are drying during the day, so the cows can rest on dry "islands" in the sun.  It looks bad though.  I was out fixing fence in our yards today, and sank into the mud as I stood still, like in quick sand.  I nearly lost my boots twice, stuck in the mud as I tried to walk out.  I've never been more grateful for the concrete portions of our yards, where are animals can find additional reprieve from the mud, as well as eat and drink in mud-free peace. 

Even if we get into the field, the mud is so severe by our silage bags, we will not be able to make our new 2011 haylage bags in the yard.  We will be searching for the highest, driest location on the farm.....it's crazy to think about not being able to put a silage bag on our pad for weeks.  So please wish us well...these soggy dairy farmers could really use a dry break for the next 2-3 weeks, then we'll take some more rain.

2011 Projects-Phase 2: The Patio!

Arrival of the feed bunks! Another muddy day!

So much rain meant Jon had to work in the rain a lot! Dedicated to get the job done!

Finished project!  Happy Cows! Success!

Since late March, we have been working diligently to start and finish our second project for 2011.  We wanted to do this project last November, but thanks to our lovely Minnesota winters, we were greeting with snow a little too early.  Late March we started moving dirt, poured concrete in April, laid the bunks in place in April, welded gates & fencing in April and let the cows out for their first night on the patio just before May began!  Our patio was inspired by a visit at a fellow dairy farmer's farm, Laura Daniels of Wisconsin.  Laura had a patio on her farm for her Jersey cows to roam out to, which allowed her to add more eating space for her cows.  BRILLIANT IDEA!  We saw this idea in October, and wanted to add it immediately, but there were some hoops to jump through...all dairy farmers have to do some serious planning before a project, even a smaller one like this.

First we started to lay out the "floor plan".  We then contacted the local county office to visit with our County Feedlot Inspector.  Our inspector came to the farm for a visit in November to check the site, overview our plans and give the "go-ahead" to start.  The primary concern for the county, with outdoor feeding, is manure run off.  We designed the patio with curbs and bumpers which keep the manure from running away, even in a heavy rain storm.  Next we contacted local contractors to bid the project and worked with our banker to secure financing.  So...why did we add this patio?!?!?! 

Easy!  We have more heifers calving each month, and we have a very low cull rate (percent of cows removed from the herd via sale), therefore each month our herd grows with additional cows-the result of excellent animal care!  Our growing herd had plenty of space in our bedded pack barn for laying down, resting and sleeping, but as we add cows the amount of feed bunk space got lower and lower.  We managed around this by pushing up feed frequently each day, as well as feeding twice a day.  The cows never ran out of feed, but the competition for feed increased.  Research recommends 24 inches of space per cow...so we added the patio.  The patio also allowed the cows to go outside to enjoy the sun and get a little exercise.  They enjoy the sun shining in on the south side of our curtain barn, but this was an added bonus!  Even on a rainy day, there's at least a couple standing out there!  Check out the pictures of the progress that got us to our final goal!  Ultimately, the new Patio allows us to continue the excellent care our cows get everyday!

2011 Projects....Phase 1

Well I have been busy, as you can see by my absence from the blogging sphere.  There are some great reasons for this, which I will explain in the coming posts.  We expect 2011 to be a great year for our farm, we have some big plans to make our farm better for our cows (first priority) and for us (second priority).  Phase 1 of our projects was to hire a full time employee or 2 part time employees to assist with milking and clean up of the parlor.  We started our search for employees locally in mid-April.  After interviewing a couple candidates we settled on 2 men to help us.  One is responsible for coming to milk in the morning, while the other assists with milking at night.  Both have the good fortune of milking with me! (haha!)  By hiring employees, we free up Jon from the responsibility of being in the parlor...giving him the opportunity to work on other projects around the farm. 

Now that we have the "kinks" worked our of our schedules and we have a more settled routine, we can see the advantages of having additional help.  In the mornings, I am able to milk cows and do cow health checks while Jon is able to feed 2 batches of TMR (total mixed ration) to the milking cows, feed the dry cows and feed our heifers all before noon!  In the evenings, Jon is able to haul manure, fix various pieces of equipment, and work with cows that need additional care.  It's been amazing how much more efficient we have become.  Because we have feed to all of our animals, earlier in the day, we have seen an increase in milk production.  Because we are able to milk our cows faster, the cows are able to spend more of their day resting, eating and drinking.  It's been great to see the cows relax and reap the benefits of such a simple change. 

Neither one of our employees have any previous experience milking cows, but we have been working to teach and train.  They are fast learners and have a great respect for our cows.  I think that's been the best part of adding employees....teaching them about how much we respect and care for our cows.  In fact, last Saturday, our morning milker brought his 10 year old son to milk with us.  It was awesome to see Clif share with his son the importance of cleanliness in the parlor, proper cow handling, and the value of agriculture in our local economy.  So, as we continue to work out the kinks, we hope to have more good news about hiring employees.