Freestall barn

Free stall barns are engineered structures, where dairy cows can be housed and provided with their daily dietary requirements and water. Free stalls are typically used to house dairy cows for extended periods and include a bedding area for cows to ruminate and rest. The term 'free stall' refers to the bedding area where cows are provided stalls (cubicles), where they may lie down.

Feed lanes and cow alleys, as well as bedding areas, are cleaned daily to maintain cow comfort, health and production performance. Internal or external loafing areas may be included in the design to provide additional area for cows to move around.

As an all-weather facility, free stall barns can significantly improve supplementary feed utilisation and herd comfort during adverse events, reducing production losses. Better herd monitoring, and a potential reduction in lameness is also possible as cows are not standing in mud or on concrete for long periods of time.

Management benefits include reduced farm maintenance costs from paddock renovation and laneway surfacing. Pasture production may increase if paddocks are protected from pugging or overgrazing (if an emphasis on home grown feed is retained). There is an opportunity to capitalise on more advanced effluent management to complement fertiliser applications.

Limitations

Free stall barns require significant capital outlay to establish, and the business can become more reliant on high quality supplements, increasing the business’s vulnerability to seasonal price changes. Typically, the business has higher input costs and is more dependent on stable milk pricing. Effluent management is a vital function of the barn and requires strict management and experience. Free stall barns are not always suitable for all cow breeds (or genetics). Herds with a range of cow sizes can make it difficult to ensure each cow has a suitably sized stall. Higher production cows may require milking more frequently than twice a day. Free stall barns often require additional regulatory requirements.

Design considerations

Choose a location that allows good access to key infrastructure and resources required to operate the barn. Consider the environmental impacts whilst supporting a cost-effective system. Free stall barns require significant investment with sound financial and business advice. A farm system using a free stall barn, that is significantly removed from a grazing methodology, requires specialised management of both cows and people. It’s not a legal requirement currently, but the Ministry for Primary Industries have consulted on rules that would require cows permanently housed to have access to the outdoors. If you’re planning to use your free-stall facility for most of the year, considering outdoor access as part of the design process will help to future proof your investment.

A feed supply management plan is required to ensure a constant supply of quality feed into the barn . A feed bunker area and the necessary machinery required to handle the variety in supplementary feed types are crucial elements to consider, depending on how the barn will be used.

The free stall barn must provide sufficient spacing for cows to provide comfort while eating, loafing (at least one free stall per cow) and resting, while promoting good cow flow and wellbeing. Ventilation and cooling systems are required to sustain cow comfort and performance.

An appropriately designed and engineered effluent management system is needed to capably handle the liquid, slurry and solids at the expected volumes.

Cow comfort

Freestalls should be designed to fit the largest cows in the herd and must allow all cows in the facility to lie without overhanging into passageways. If you see cows lying down in other areas such as passageways or crossovers or are perching (standing with their front legs in the stall and their back legs in the passageway) this could indicate the stalls are too small, or there are not enough. A minimum of one stall per cow must be provided, and an extra 10% is recommended to allow submissive cows better access to lying. Freestalls are not suitable for calving.

Cow cleanliness

Maintaining clean stalls (beds) is crucial for cow comfort and health. Free stall barns are better suited to herds with uniform cow size. Dirty stalls can lead to cows lying in wet dung, increasing the risk of infections and discomfort. Smaller cows may soil the backs of the beds and daily scraping of the backs of beds is essential.

Proper stall length is vital to prevent cows from flicking effluent onto their flanks. Trimming cow tails can help, but adjusting stall length and width is more effective. If all the beds and cows are getting dirty, it may help to observe the cows and alter adjustable neck rails and brisket locators.