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Future-proofing the family dairy in America

One family dairy in the heart of Wisconsin has future-proofed its business by transitioning to crossbreeding with ProCROSS and robotic milking.

Running a UK-sized dairy herd in the vast and intensive landscape of American agriculture might seem like swimming against the tide—but one U.S. operation is proving that smaller doesn’t mean less progressive.

Dornacker Prairies is a 360-cow dairy in Wisconsin run by fifth-generation farmer Allen Dornacker and his wife, Nancy, in partnership with Allen’s parents, Ralph and Arlene.

Like a growing number of UK farms, they have embraced technology. In 2018, the Dornackers transitioned to robotic milking, installing three Lely A5 robots inside a purpose-built cubicle shed. The size is actually typical for the USA, where the average dairy milks 350 cows. Although it is still somewhat bigger than the UK where average herd numbers have edged to 219.

The State of Wisconsin ranks second only to California for milk production, with more than one million cows milked across 6,500 farms. Unlike Californian dairies, which rely heavily on importing feed thousands of miles from the Midwest Corn Belt, Wisconsin’s climate allows producers to grow the majority of their own.

The Dornackers farm over 1,000 acres—owning 380 and renting the rest—allowing them to be 90% self-sufficient in feed. They grow 220 acres of soybeans, 280 acres of alfalfa, 360 acres of maize, and 150 acres of winter wheat.

In 2022, they expanded, installing three more robots to replace their traditional double-six herringbone parlour. The facility has capacity for up to nine robots, future-proofing the business for the couple’s four children: Kate (17), Jack (15), Adam (14), and Anna (12).

As part of the expansion, slurry storage was increased to hold one year’s worth of waste. Composting muck and incorporating it into green cover crops has reduced nitrogen requirements by 80% and decreased reliance on fungicides.

The business employs four full-time and four part-time staff across its dairy, arable and beef enterprises, with dairy cross beef calves also reared.

ProCROSS cows in the barn
We switched because the Holstein wasn’t lasting long enough, and we were getting too many metabolic issues and had too many cows doing the splits.

Allen Dornacker,
Owner of Dornacker Prairies, USA, 360 ProCROSS cows

About the barn

While the summer climate provides the ideal growing environment for soya and maize, Wisconsin’s weather means shed design must be carefully planned to minimise cow stress and maintain performance year-round.

The  3.62m €  barn boasts 400 cubicles and has an insulated roof, automated side curtains and high-speed fans designed to withstand freezing winters or hot and high humidity in the summer, when the temperature heat index can quickly climb to 70-80.

Allen says the temperature varies from -17C to 37C between the winter and summer.

Automated scrapers are used to keep alleys clean, while robotic feeders operate seven times daily, keeping the ration pushed up along the central feed passage.

On either side of the feed passage is a double row and single row of deep-bedded sand cubicles with a straw-bedded area for close-up calvers and a fresh-cow pen.

CowLocator technology, combined with Nedap tags and Lely Horizon software, allows real-time location of cows via a smartphone.

Cows are fed up to 6.3 kg of feed inside the robots, with visits averaging 2.7-3 times daily. The rest is supplied in the total mixed ration (TMR) with the feed rate averaging 0.33 kg of concentrate per litre of milk.

Herd production averages 13,725 litres at 3.25% protein and 4.18% butterfat. Milk is supplied to Cedar Valley Cheese. Cell counts average 120,000 cells/ml with a bactoscan of 4.

Dornacker ProCROSS farm

Breeding for longevity and profitability

Unhappy with the poor cow longevity, the Dornackers began crossbreeding in 2016.

“We switched because the Holstein wasn’t lasting long enough, and we were getting too many metabolic issues and had too many cows doing the splits.”

Holsteins were bred to VikingRed, and the resultant progeny was mated to Coopex Montbeliarde sires to create a three-way cross.

Within one year, dead-on-arrival rates fell from 8% to 2.5%, and metabolic disease has halved to less than 1%, says Allen.

“The first thing we noticed is the vigour of calves was phenomenal,” he says.

Pregnancy rates average 38% annually. This has been boosted by crossbreeding and the introduction of the Lely heat-time detection system. Conception rates average 50%, with ov-synch only used on 10-20% of cows that are more than 140 days in milk and still open.

Cows are rebred 75 days after calving, or sometimes 90 days for higher production animals.

Sexed semen is used on maiden heifers – these achieve 60% conception to first service. High-production, first-lactation heifers are also served to sexed, alongside the best-ranked animals, with the rest mated to Aberdeen-Angus.

Allen explains: “I use Lely’s production efficiency index which produces a minimum herd value based on health, production and reproduction. A value of 700-800 is a good cow, and anything under 400 is bred to Angus.”

Cows are largely voluntarily culled for poor milking speed or production, with Allen running an annual cull rate of 30%.

“Our cull value with the crossbreds is higher compared to the Holsteins.”

Typically, all steers are raised to 18 months, but they have changed tact due to the high beef prices.

“We have been getting   843 € for a day-old calf, so we have been selling them before weaning,” explains Allen.

A decline in the US beef cattle herd to 28.2 million, down 700,000 since January 2023, has raised prices with drought and high input costs leading many ranchers to sell breeding females.

Allen says he is receiving£3.85/kg for Holstein-bred calves, an additional 19¢/kg  for ProCROSS-sired progeny and  5.04 €/kg for Angus-sired dairy crosses.

All of this is contributing to better profitability.

Discover ProCROSS
ProCROSS cows

Future-proofing the family dairy in America

Dornacker Prairies is a 360-cow dairy in Wisconsin run by fifth-generation farmer Allen Dornacker. Alan made the switch from Holstein to ProCROSS in 2016, after becoming frustrated with poor longevity and high levels of metabolic disease.

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