Planificación para mantener limpios los pasillos de Hamra Farm
How clean alleys support cow comfort, efficiency, and sustainability at Hamra Farm
Clean alleys might not be the first thing you think about when planning a barn, but their impact quickly becomes clear in everyday work. Alley cleaning plays a key role in cow comfort and hoof health, while also influencing daily workload and how smoothly cows move through the barn. Slippery floors, dirty legs or blocked systems quickly highlight where routines or barn design fall short.
During the Hamra Farm Expansion Project, we focused on manure handling and robotic collectors when designing the new barns, to ensure alleys stayed clean. Well‑planned manure handling and robotic collectors were fully integrated into the barn design, supporting clean, dry walking surfaces that promote cow comfort and hoof health, while ensuring reliable daily operation and efficient barn management. By bringing together automated solutions, robust engineering and a closed manure loop, the approach shows how deliberate planning supports both cow comfort and overall farm performance.
Below, we break down how those choices were made – what was prioritised, and why it matters in daily barn operation.
Alley cleaning in the VMS Barn
In the video, William Eriksson, Market Area Development, Eastern Europe, DeLaval, shows us around the VMS Barn at Hamra Farm and explains how alley cleaning is planned and managed to keep walking surfaces clean, dry and safe for cows.
Why clean alleys matter for cow health, behaviour, and productivity
For dairy cows, the condition of the walking surface plays a central role in health, behaviour, and productivity
Risk of injury
Wet or contaminated floors increase the risk of slipping and place additional strain on claws and joints, raising the risk of lameness and claw horn lesions over time. Cows may hesitate, shorten their stride, or avoid certain areas altogether, disrupting cow flow.
Behaviour changes
When walking becomes uncomfortable, cows may stand longer, delay visits to feed or water, or be less willing to walk to the milking robots. In automated barns, this can reduce voluntary robot visits and increase the need for fetching and intervention.
Hoof and udder hygiene
Clean alleys reduce prolonged contact between claws and manure, supporting hoof hygiene and lowering infection pressure. Cleaner walking areas also improve udder and teat cleanliness — particularly important in VMS barns.
Productivity
Clean, dry alleys support smooth movement between lying areas, feed, water, and milking robots. This helps cows maintain regular feeding and milking patterns, supports consistent milk production, and reduces manual intervention in automated barns.
Clean alleys with manure robots in the VMS Barn at Hamra Farm
In the VMS Barn at Hamra Farm, manure is handled using DeLaval robot collectors, chosen specifically to meet the demands of automated milking. Instead of pushing manure along the alleys, the robots collect it directly from the walking surface and transport it away. This reduces contact between manure and hooves compared with conventional scraping systems.
We operate four DeLaval robot scrapers in the VMS Barn – three in the main cow area and one in the VIP area. Each robot is assigned to a specific area of the barn and follows its own predefined cleaning route, supporting predictable operation and reliable manure removal across the different zones. Our manure handling system is designed to operate reliably at full barn capacity (350 cows), ensuring performance remains stable as cow numbers increase over time.
This type of manure‑handling set‑up is particularly important in barns with automated milking systems, as alley conditions have a direct impact on cow flow. Cows need to feel confident walking to and from the milking robots throughout the day and night. Slippery or heavily soiled walking surfaces can reduce voluntary robot visits and increase the need for fetching and manual intervention, affecting both labour efficiency and overall system performance. Consistent alley hygiene helps maintain smooth cow traffic and supports the milking system operating as intended.
Parking and charging stations
Each robot has its own parking and charging station.
During charging, the robots automatically empty the collected manure into a drainage pipe that leads to the VMS Barn reception pit, which receives manure exclusively from the VMS Barn.
The other barns – the Heifer Barn (young stock) and the dry cow/maternity barn – each have their own separate reception pits. In total, the farm has three reception pits, one for each barn. All reception pits are equipped with manure pumps that pump the manure to the lagoon.
Reception pits
During charging, the robots automatically empty the collected manure into a drainage pipe that leads to the VMS Barn reception pit, which receives manure exclusively from the VMS Barn.
In total, the farm has three reception pits. The Heifer Barn (young stock) has its own reception pit, while Elly’s Dry Cow Barn and the Maternity and Calf Barn share one reception pit. All reception pits are equipped with manure pumps that transfer the manure to the lagoon.
Designed for frequent, consistent cleaning
Our setup allows alleys to be cleaned continuously throughout the day, including high‑traffic areas such as crossings.
In the VMS Barn, manure handling is designed to remove manure frequently across different barn zones – typically every two hours – rather than allowing it to build up before removal. This helps prevent manure from drying, compacting, or spreading further through the barn, particularly in areas where cows move and gather most.
In practice, we find that this approach supports:
- Cleaner, drier walking surfaces, which help cows move more confidently and comfortably throughout the barn.
- Improved hoof and leg cleanliness, reducing prolonged contact with manure and supporting long‑term hoof health.
- Smoother cow flow, especially around robot entrances and other high‑traffic areas, with fewer hesitant or reluctant cows.
- More consistent feeding and milking routines, as cows are more willing to move between lying areas, feed, water, and the milking robots.
- Reduced need for fetching and manual intervention, improving day‑to‑day labour efficiency in an automated barn.
- Easier observation of movement and gait, making it simpler to spot early signs of discomfort or mobility issues.
- More stable conditions across seasons, even when manure volumes and moisture levels vary.
The result is cleaner alleys, calmer cow movement, and a barn environment that supports animal comfort, productivity, and efficient daily management.
The planning of the alleys supports good hoof care. Because the manure robot collects manure instead of pushing it, cows have cleaner hooves and legs, which benefits both hoof and udder health. The robot moves slowly and is easy for cows to pass, helping create a calm atmosphere. Alley mats in most alleys also support good hoof care, provide secure grip, and support natural cow behaviour.
Linda Thulin
Manure handling also works hand in hand with flooring design.
Comfortable walking surfaces that support natural behaviour
In the VMS Barn all alleys except the feed table areas are fitted with 18 mm rubber alley mats, providing a comfortable, non‑slip surface that supports natural movement and reduces strain on joints and claws. The feed alleys are intentionally left without rubber mats to promote natural hoof wear, supported by regular hoof trimming as part of routine herd management.
Together, flooring choices and effective manure removal help support animal welfare, confident cow movement and smooth day‑to‑day herd management in the automated milking system.
A closed effluent system to reduce emissions
From the moment manure is collected, the effluent system at Hamra Farm operates as a closed loop. Both the reception pits and the lagoon are covered, limiting contact between manure and air and helping reduce ammonia emissions, odour, and nutrient losses. By keeping manure enclosed, emissions are reduced, odour levels are kept lower, and valuable nutrients are preserved.
From the reception pit, manure is pumped to the lagoon through a large‑diameter pipe system. Thorough agitation ensures a homogeneous consistency, improving pumping efficiency and reducing the risk of blockages. Reliable operation at this stage is essential, as disruptions quickly affect the entire manure handling chain.
Here’s how alley cleaning is handled at Hamra Farm.
In this video, Gökhan Kaplan, DeLaval solution specialist for barn and manure systems, explains how the manure set‑up keeps the alleys clean.
Durable manure handling in the young stock barn
While collector‑based manure robots are used in the VMS Barn, alley cleaning in the young stock barn is handled using conventional scrapers with a heavy‑duty chain system.
This solution has been selected to match the housing design, cow flow and management routines in the young stock barn. Cow movement is more predictable, layouts are simpler and continuous access to milking robots is not required. In this context, a robust scraper system provides an effective, durable and low‑maintenance way to keep alleys clean.
The scraper setup differs from the manure robot solution in the VMS barn, where flexible, frequent and targeted cleaning is needed in high‑traffic areas around robots and crossings. Using different systems in different barn areas allows manure handling to be adapted to specific needs while remaining part of one integrated overall concept.
One farm, different solutions – one overall concept
There is no single best solution for cleaning freestall alleys. Flush systems, scrapers and collectors all have a role, depending on barn design, bedding, labour availability and management priorities.
At Hamra Farm, manure handling reflects those differences:
- manure robots in the VMS barn
- conventional scrapers in the young stock barn
- a closed effluent system supporting storage and nutrient management
Clean alleys are not just about hygiene. They form the foundation for cow comfort, reliable daily routines and sustainable farm performance — today and over the long term.
Alley‑cleaning options in dairy barns
What alley‑cleaning systems are commonly used in dairy barns?
Several systems are used to keep walking alleys clean, depending on barn design, climate, and management preferences.
What are traditional mechanical alley scrapers?
Traditional mechanical systems, such as hydraulic, chain or metal scrapers, pull manure along the alley to a cross channel at set intervals. These systems are robust and widely used, particularly in colder climates, but typically clean at fixed times rather than continuously.
What is water‑based alley flushing?
Water‑based flushing systems use large volumes of water released at intervals to move manure through channels into collection or separation systems. While effective in suitable climates, flushing relies on reliable water availability, and sufficient drainage capacity.
What are manure robots?
Manure robots are autonomous units that clean alleys repeatedly throughout the day. They allow flexible cleaning frequency and targeted operation, helping maintain cleaner, drier walking surfaces without disturbing the cows.
Why water‑based alley flushing is not used at Hamra Farm
Why has Hamra Farm chosen not to use water‑based alley flushing?
At Hamra Farm, water‑based flushing systems are not used due to climate conditions, sustainability considerations, and local legislations.
How does climate influence this decision?
In long, cold winters, flushing systems are exposed to freezing risks in alleys, channels, and pipework.
What about water use and manure management?
Flushing systems require large volumes of water and sufficient storage capacity. At Hamra Farm, manure handling is designed as a closed, mechanical system to minimise water use, support controlled nutrient management, and reduce emissions from exposed manure.
Key takeaways
Here are some of the key takeaways from how alley cleaning has been planned and managed at Hamra Farm:
- Clean alleys are fundamental to cow comfort – dry, non‑slip walking surfaces support confident movement, reduce strain on claws and joints, and help maintain natural cow behaviour.
Frequent, consistent cleaning matters more than occasional scraping – regular manure removal prevents build‑up, reduces slipping risk, and keeps high‑traffic areas functioning smoothly.
Manure‑handling choice must match barn function – robot collectors support flexible, targeted cleaning in automated milking barns, while robust scrapers are well suited to young stock areas.
Flooring and manure handling work together – rubber alley mats combined with effective manure removal support hoof health, grip and natural movement, while un‑matted feed alleys promote natural hoof wear.
Clean alleys support system performance, not just hygiene – good alley conditions keep cows willing to move to feed, water and milking robots, reducing the need for fetching and manual intervention.
Closed effluent systems support sustainability goals – enclosed manure handling helps reduce emissions, odour and nutrient losses while supporting reliable long‑term operation.
Coming up next in our blog series: A closer look at the DeLaval Swinging Cow Brush (SCB) and how cow grooming supports comfort, behaviour, and welfare at Hamra Farm.
Stay tuned.