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Case Studies - iDairy® Farm

The project listed here are a snapshot of what we have done over the years, projects are listed in year order, latest ones first, older ones last.

A snap shot of a project may give you a quick way to establish if any of our make farming ezy product solutions would work for you. We can also put you in contact with the farmer related to the project if you feel its beneficial to have a chat.

Click below for Environmental Case Studies.
Environmental

delivery to siteGeotextile protection down, ready for roll outRoll out and install fittings
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350 Cube Effluent Storage 

Year Completed: 2021

Location:

Reporoa area

Objective:

provide easy care storage bit further awau from the dairy to irrigate farm paddocks further afield 

Solution:

350 Cube round effluent storage with Flecitank Round 

 

Recycling Nutrients saves having to buy fertilisersEcobag can come in various shapes and sizes from 1000 Cube to 15000 CubeDigging started Dec 2020, 3.5 meters deep 45 X 45 meter  squareStraps tiedLifting in of the 8 ton EcobagInflation and installation of man holesAfter tie down of straps we have a look inside see if all aligned properlyAfter check we deflate the systemJob done
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8000 Cube Ecobag Nutrient Capture and Re Use


Largest totally enclosed effluent system in NZ 

Year Completed: 2021

Location:

Otautau 

Objective:

To store all cowhouse effluent over winter and early spring and ability to use this on farm as natural fertliser and organic matter. Wageningen (NL) research indicated cowhouse effluent means 50% of nutrients are available straight away, the other 50% is slow release. Soil carbons in the form of organic matter is build up over time.  

Solution:

8000 Cube enclosed Ecobag Nutrient capture and storage system. This system is fully approved by the Southland Regional council. A new standard in non crusting, none smelling storage is now set. 


Instalation completed Feb 2021

 

Work in progress new yardComing along nicelyBack ground shed, new yard in front
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Dairy Shed Upgrade with Dungbuster, new gate, drafter and Teatspray unit. 

Year Completed: 2021

Location:

Australia Victoria 

Objective:

Create time and resource savings for this dairy. 

Solution:

An integrated backing gate and dungbuster was provided for this new dairy renovation including pre cast for sump and drain.


Drafter ( 3 way) and Teatspray unit for better cow management and cow udder health

 

Two DungBusters in the same yard... no problem!!Motor and filter also need to be checked.Filter pretty dirty, but just needs a clean.Bar placed in vice for cleaning. Waterblasting with a needle nozzle into the small holes removes most of the grit, then a fan nozzle to clean all the outside.Occasionally we find more than a bit of muck or grit!Using a small gauge file will remove any hard blockages in the holes.Clean as a whistle and ready to be bolted back onto gate.
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  DungBuster Servicing

Year Completed: 2020

Location:

Gordonton, Waikato

Objective:

  New owner wants the DungBuster checked and serviced. Some of the bars not cleaning well.


  Had little maintenance over the years.

Solution:

Remove all bars and clean thoroughly, check for blockages, check backing gate motor and filters. 

 

driver units visible at end of lanes (outside)
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Cowhouse Installation new scraper system 

Year Completed: 2020

Location:

Raglan 

Objective:

After the old system had done an estimated 300.000 Km of scraping over many years it was time to replace the old chain system with a more modren and easier to manage rope system 

Solution:

Rope scrapers managed per lane for best utilisation of use, when outer lanes not used the scrapers do not have to operate thus savig on wear and tear. ( multi lane loop systrems require the scrapers to run regardless of use) 

 

Line up, trailer and bike ready for the trip to the paddockRobust and Solid system, made to lastDetailed functionality
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Calf weight monitoring crate and trailer 

Year Completed: 2020

Location:

Rangiora 

Objective:

Establish entry / start weights for new calves to ensure target weights are reached. 

Solution:

A mobile calf weigh crate on trailer with panels to create a small pen for holding the animals in the paddock.


EID scanner and weigh system all integrated. Robust and easy to use 

 

Before... note aluminium extrusion very close to wearing on concreteJust got it before its too late!Just needs a bit of TLC!Check filters. This one needed replacing totally, see next picture.Filter incorrectly replaced by other servicing company. TechniPharm has the right stuff...Much better.Spotless, oil okay and ready for another season.Done!!
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DungBuster servicing

Year Completed: 2020

Location:

Putaruru, Waikato.

Objective:

Service old DungBuster unit to make like new again.

Solution:

New blades, new fittings and all just in time!

 

The shed and pizza style pensTwo feed stations per pen, all clean and tidyRobot in actionHappy CalvesReady for an other drink ?
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Robot Automatic Adlib Feeders 

Year Completed: 2020

Location:

Waikite Valley Rotorua 

Objective:

Feed dairy replacement and beef calves to 100 Kg. 

Solution:

3 Robot Automatic Adlib feeders are set up to feed milk powder and waste milk to approx 400-600 calves each year. The Feeders are part of a comprehensive rearing program.


This property has used Robot feeders for 15 years and recently upgraded to new units.


The feeders are set up on a small garden shed in the centre of a pizza style pen configuration, each pen holds approx 20-30 calves which are supplied by 2 feed stations. Each Robot can supply 8 Feed stations.  

Client Testimonial:

Name available on request 

 

Scraper at workDrive unit shown
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Scraper reconditioning 

Year Completed: 2020

Location:

Studholme Canterbury 

Objective:

Recondition scrapers in 300 Cow Cowhouse. These scrapers done 10 years of hard work in a hybrid cowhouse without much mainteance, moving over 12000 Cube of sludge per year that is 120.000 Cube of sludge moved! that is a lot of #$%^&*

Solution:

Some parts news some parts reconditioned to get more life from good solid steel work which fundamentally is sound and to good to just row out.

 

System near full spring 20201400 Cube effluent ready for irrigation to pasture
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Effluent Storage for Hybrid Farm

Year Completed: 2019

Location:

Ohaupo

Objective:

Extra storage on small strip of non-utilised land next to dairy housing.

Solution:

Customised Flexitank with rounded ends and narrow width.

 

The overall planEntry to existing loading ramp3600 entry lane gateMidrange HandlerNew grip catwalkCurve race to Handler
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Dairy Conversion Smart Yard

Year Completed: 2019

Location: Corromandel

Objective:

Use of existing unused dairy shed at run off to provide for new handling facility for
young stock and beef

Solution:

A compact design Smart Yard system with easy flow and great handling facility

 

Under constructionFinal productExisting Structure wooden retainer walls only, concrete blocks added for separation and back wall
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Presto Shed Feed Storage Bin

Year Completed: 2019

Location: Rerewhakaaitu

Objective:

Provide removable roof for existing structure bins with objective to keep feed dry and clean

Solution:

PrestoShed Roof ( retractable) with gutters for rain diversion. New divider wall and rear wall ( concrete blocks)

 

Concrete read stamped for best tractionBuild in progressHandling area, note concrete catwalksLead in to Force areaBirds eye, note effluent collection on RH side
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Youngstock and Dry Cows Handling Yard Large Capacity

Year Completed: 2019

Location: Hunter Waimate

Objective:

Large mob handling for range of stock ranging from weaners Waiugu X, dairy heifers and dry cows frequent use, collection all effluent

Solution:

High performance hydraulic handling system with Auto drafter under covered (previous sheep shed) and large mob lead in pens Full EID.
Full Effluent containment. Concreted area 300 m2

 

Firstly, we need some details.On site, first job is to set the DungBuster parts out.To enable the bars fit under the backing gate motor, we need to change the saddle.Attach droppers to gate frame with arms attached to the bars using parts provided.Attach filter(s) to gate. Also attach the solenoid for electric backing gates. An electrician will be needed to wire up any electrical parts.Attach U bends and end bungs.
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  New DungBuster Install

Year Completed: 2018

Location:

  Examples from several installs around the country

Objective:

   Install new DungBuster

Solution:

-

Client Testimonial:

-

 

Embankment preparationEcobag rolled out ready for inflation for placement and securing to embankmentGeneral overview
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Effluent storage high rainfall area 

Year Completed: 2018

Location:

Mamakus Tauranga/Rotorua 

Objective:

To provide 2000 Cube storage for new dairy in high rain fall area.


Open pond system would require double the storage and significant more pumping cost 

Solution:

2000 Cube totally enclosed ECOBAG nutrient capture system 

Client Testimonial:

Available on request 

 

Embankment preparationEcobag rolled out ready for inflation for placement and securing to embankmentGeneral overview
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Effluent storage high rainfall area 

Year Completed: 2018

Location:

Mamakus Tauranga/Rotorua 

Objective:

To provide 2000 Cube storage for new dairy in high rain fall area.


Open pond system would require double the storage and significant more pumping cost 

Solution:

2000 Cube totally enclosed ECOBAG nutrient capture system 

Client Testimonial:

ze: 14px; font-family: verdana, sans-serif;>Inside listening to the rain falling with the knowledge that it will not be filling up the Ecobag with fresh water that I have to pump out.

ze: 14px; font-family: verdana, sans-serif;>Maintenance of the Ecobag in two years is almost none. some weed spraying around the edge to keep place looking smart.

ze: 14px; font-family: verdana, sans-serif;>The major benefit of the Ecobag in our high rainfall area ( over 3 m /year) is reduction of surface rainfall collected. I our case over 2 m l /year would fall on an equivalent pond which has to be pumped. We would fill an conventional pond over twice per year with rain water.

ze: 14px; font-family: verdana, sans-serif;>We spraying the stored effluent onto pasture during summer/ autumn period, ensuring the bag is empty by the end of the season. Having our 2 milion L  bag empty at the start of the spring season is great, we can just store effluent until ground is dryer and staff have more time to irrigate. By the way we have never even looked like filling the bag, max it has been is around the 75-80% full.     

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ze: 14px; font-family: verdana, sans-serif;>Several of the staff have young children which like to play on the farm. Ride bikes on the concrete yard moving to motor bikes etc. We have confidence with the Ecobag there is no danger to the youngsters. 

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ze: 14px; font-family: verdana, sans-serif;>Being a forestry conversion farm we can see the benefits of the nutrients from the effluent. We have not done any work on if there is any more saving of nutrients I.E. nitrogen from less gas losses. 

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ze: 14px; font-family: verdana, sans-serif;>In summary. Over the last two years minimal maintenance, significant reduction in volume pumped due to no rainwater, Staff can empty when calving pressure is reduced and finally but most significant is the improved safety.    

ze: 14px; font-family: verdana, sans-serif;> 

ze: 14px; font-family: verdana, sans-serif;>Kind Regards

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Lachlan McKenzie
289 Kapukapu Road
RD6 Rotorua
3096
Mobile: +64 21 382 442



 

explanation of flowBirds eyel view to completed project
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Yards for Dairy Grazers and Beef fattening,  Waikite Valley 

Year Completed: 2016

Location:

Waikite Valley Rotorua 

Objective:

Integate yards to existing lead in and lay of the land

Solution:

Navigator Force yard, curved race and load out, draft pens to main lead in.


Midranger Handler and 3 way drafter 

Client Testimonial:

Great set of yards works really well. 

 

Offside showing side & vet gatesOperating side with scale monitor standSplit entry gate with single handle operationOverall view on operating side
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New Dairy, new Supreme Handler

Year Completed: 2016

Location: Opunake

Objective:

To make handling, weighing, hoof trimming as Ezy as possible

Solution:

Top of the line Dairy handling for new shed

 

The large concrete lined pond and stirrers placed strategicallyLevel changes allow for full pond mixing to occur
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Stirring 12000 Cube of Cowhouse Effluent 

Year Completed: 2013

Location:

Leeston 

Objective:

12000 Cube of effluent is a lot of effluent in any ones terms, but when it contains high solids its even more challenging. Storing requirements for up to 7 months and maintaining an homeginised consistancy for pumping and dribble boom distribtion 

Solution:

3 times 22 Kw Eisele High Performance Stirrers strategically placed and with ability to change level height of stirring so all levels of the pond can be stirred and mixed properly  

Client Testimonial:

Available on request, as of Dec 2020 the stirrers have not been touched for maintenance other then oil changes. 

 

Science happens every day
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Dairy Research 

Year Completed: 2010

Location:

Hamilton. Palmerston North, Lincoln, Southland 

Objective:

Support handling systems for research 

Solution:

Dairy Handler systems with specialist customises options for research users

 

Soil turned first concrete inBuild in rapid progressAlmost thereMilking !Cowhouse 600 cows linked to Dairyshed
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New Dairy Shed

Year Completed: 2010

Location: Glenavy

Objective:

To create a modern high volume throughput Rotary dairy milk harvesting platform and related animal management system aswell as interlinking race and effluent system to Cowhouse

Solution:

1) Rational and clear specifications created for maximised output and value for money for client
2) Transparent comparisons of price V value from 3rd party contractors
3) Engage contractors and execute plans and build
4) Deadline 1 July and transfer from old shed to new shed within 12 hours achieved

 

Handler, drafter and load outCurve race and work in progressYard system overviewForce pen and 360 gate in action
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Dairy Support yards Tapanui 

Year Completed: 2009

Location:

Tapanui SI 

Objective:

High volume young stock yards for replacement dairy herd

Solution:

Full yard and Dairy handling, drafter and load out, main features Curve race and initial 360 force yard, Supreme handler which later on went to the Dairy farm and was replaced with a Hydracommander handler

 

Used for everything under the sun Dairy Caddy is topsUsed by many vets and carried on the tow bar ready for the next jobAn easy step up was developed in 2017Great work safely done every time !
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Safe support frame/stool for Tailpaint, cow test and AI in Herringbone shed

Year Completed: 2001

Location: Nationwide

Objective:

To create a movable support frame for farmers to easily tail paint, pregames test, AI and read air tags

Solution:

The Dairy caddy ™ concept was originally provided from a 450 raised platform which then over the years evolved to a 650, 700 and extendable version, fully braked and mobil so it could be move along the pit wall. Various innovation awards have been received for this innovation and many thousands are in use throughout NZ Dairy Sheds

 

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Cowhouse Wintering Barn

Year Completed: 2000

Location:

Otautau 

Objective:

1998-2000

Solution:

One of the first wintering barns in Southland. Initial discussions and design criteria were to create a cost effective model for NZ conditions and economic models. Supply of all sludge pumping systems.

 

The overall plan and view from the hillEasy oversight from all anglesWorking the weights is easy as
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Figure 8 yard

Year Completed: 2000

Location: Taumarunui

Objective:

Create a high performance efficient handling facility for a dairy herd and replacement stock

Solution:

Figure 8 yard with electric backing gates full console control