Milking robots have become a game-changer for dairy farmers, offering increased yields, improved animal welfare and data-driven insights. However, there are also challenges related to the use of these automated systems.
In this blog, we’ll explore the evolution of milking automation, its current state and five of the key challenges facing farmers adopting this technology.
A 60-second history of the automation of milking
The automation of dairy milking has evolved significantly over the past century, driven by the need for increased efficiency and reduced labour on farms. The process has evolved from a handheld pump invented in 1860 and then followed by other mechanical upgrades, to the automatic milking systems that were installed in the 1990s.
Nowadays, these systems use robotics, vacuum technology, numerous sensors and more to extract milk, significantly reducing the time and labour required for milking. The technology has continued to advance rapidly, with major manufacturers like GEA, Lely and DeLaval continually refining their systems.
Source: GEA
In 2024, the milking robots market is valued at US$3.2 billion p.a. and is projected to grow to US$5.3 billion by 2029. The market is largest in North America, Europe (particularly western Europe) and Asia-Pacific.
The use of milking robots in dairy farming has become increasingly necessary due to several factors, primarily the need to reduce labour costs. There is also a drive for greater productivity – this is boosted by providing a consistent, round-the-clock milking process, which can be tailored according to each herd and used for ever-increasing herd sizes.
Alongside this, milking robots have other advantages, such as:
- Improving milk quality and hygiene by using consistent milking protocols
- Improving cow welfare by reducing stress during milking
- Providing continuous monitoring of the herd’s health through analysis of milk quality and other metrics, enabling the early detection of any illnesses or problems.
How does a robotic milking system work?
Very briefly, milking robots generally work as follows:
1. A cow walks into a milking stall – either voluntarily or when it is instructed to by the farmer – where its identification tag is read and recorded.
2. The milking robot’s arm swings underneath the cow and sterilises each teat before using suction to attach milking cups. These actions are guided by sensors and stored.
3. A vacuum sensor detects whether the cup is fitted correctly and a flow sensor detects whether there is a flow of milk. If not, the cup is detached and then reattached. The flow sensor also indicates when the milking has finished so that the cup is then released.
Source: Delaval
4. The cow’s milk is tested before being either stored or, in the event of any non-conformances, diverted to the dump bucket.
5. The robotic arm is withdrawn from the stall, the gate opens and the cow exits the parlour.
6 challenges with milking robots that must be solved
1. High initial investment costs
This is usually the big one. As with any technological development, milking robots inevitably require significant capital investment. While this outlay is well within the reach of large dairy operations (or ‘mega-dairies’), it is particularly a concern for small and medium-sized farms in emerging economies.
However, the cost can be reduced by buying second-hand units or through leasing options, for example.
Also, there are maintenance costs to consider. The equipment might be running 24 hours a day, 365 days a year, so there will inevitably be wear and tear. Plus, the wide range of electronic components that are needed – such as lasers, sensors and 3D cameras – can be expensive.
Ultimately, however, the costs of installing milking robots should be compared against ongoing costs of non-automated systems (e.g. labour). Plus, factor in that yields are likely to increase when cows are being milked more regularly. Lely suggests that yield will increase by around 20% if the farm is milking twice a day with a robot.
2. Design
Creating robust and reliable milking robots presents a unique set of engineering challenges. A milking parlour is unavoidably a dirty environment and cows are large, heavy creatures. So, the milking robots need to be rugged enough to withstand kicks and bumps, yet gentle enough so as not to hurt the animal.
The design must account for varying udder shapes and sizes, as well as the cow’s movements during milking. Sensors and imaging systems must accurately locate teats in real-time, even when obscured by dirt or hair. Also, the robotic arm must navigate around the udder smoothly and attach the cups precisely without causing discomfort.
Hygiene is paramount, so the system must include effective cleaning mechanisms for both the robot and the cow’s udder. And reliability is crucial, as breakdowns can disrupt the entire milking schedule and stress the cows.
So, components must be reliable, durable and easily maintainable to ensure continuous operation.
3. Operation
Converting to an automated system that uses milking robots involves the overhead of training the cows so that they grow accustomed to the equipment. But machinery that is quiet, gentle and predictable – without shouting or waving, like a human – is often viewed favourably by a cow.
Despite the system being automated, it is inevitable that the farmer’s input will still be required at times. In this case, the system triggers an alarm, which notifies the farmer of a problem – for example, in the event of a robot having a blockage or faulty sensor. But system alarms are customisable and can be tailored according to specific needs or times of the day. Nevertheless, alarms are vital for ensuring the continued operation of an automated system.
Another consideration is that the operation and maintenance of milking robots require a specialised skillset that farmers might not possess. Many farmers will develop these skills over time and, once again, any related costs should be considered alongside the savings in other areas.
Finally, the occurrence of contagious organisms can be more difficult to manage when milking robots are used, largely due to the amount and complexity of equipment involved. But this should be offset against the consistent and reliable early warnings that the system will provide.
4. Cow health monitoring
Milking robots offer significant potential for monitoring cow health. These systems can continuously assess various health indicators during milking, providing farmers with valuable real-time data. For example, by analysing milk composition, robots can detect early signs of mastitis through automated cell counting.
Robotic systems can also track fertility cycles by measuring hormonal changes in milk, aiding in optimising breeding schedules. Plus, integrated cameras and sensors allow for close observation of each cow, potentially detecting signs of lameness, stress or other behavioural changes that might indicate health problems.
But it isn’t a perfect science as the accuracy and reliability of the monitoring can be an issue. For example, there might be false positives identified in the herd – similarly it’s possible for a problem with a cow to be missed by the robot.
Nevertheless, this technology is improving all the time and, alongside the farmer’s own wealth of expertise, milking robots are a valuable tool for monitoring the health of the herd.
5. Data overload for farmers
Nowadays, the use of automated milking systems generates a large volume of data about a herd. While this wealth of information can provide valuable insights into herd health, productivity and individual cow performance, it can also create a data overload problem for farmers.
They can find themselves overwhelmed by the sheer quantity and complexity of data and struggle to see underlying patterns. Interpreting this information effectively requires new skills and knowledge that many farmers may lack. So, there’s a need for training programmes and user-friendly software interfaces to help farmers understand how to, first, tailor the data to their own needs and, second, use this data effectively.
Additionally, data integration across an ever-increasing array of farm management systems can be complex. Ensuring data security and privacy is another concern, especially as farms become more connected to external networks and service providers.
However, mastering this data can lead to more informed decision-making, increased productivity, as well as improved cow health and herd management.
6. Over-production and over-reliance on mega-dairy technology
Milking robots – with their greater efficiencies and lower labour costs – have unquestionably increased the supply of milk to the market. But the vast mega-dairies powered by robotics have also threatened smaller producers and the diversity of the farming landscape.
They have driven the price of milk to an all-time low in some countries, resulting in some farmers being unable to recoup their production costs. This situation is clearly unsustainable and has led to many smaller farms shutting down, with more likely to follow.
But the more flexible and accessible robotic milking solutions become, the more they will be able to address the labour and productivity challenges that dog many farming communities around the world.
Meeting the needs of different kinds of farmers and their herds operating in a vast international market, will require all kinds of collaboration between agtech design and manufacturing specialists.
This kind of tech could break open lucrative new markets and support a more diverse and sustainable approach; that will make cattle farming more humane and productive for more farmers.
