How High-Producing Herds Do It

By Jane Fyksen
Friday, November 3, 2006 4:21 PM CST

Here's how owners of three high-producing herds are maximizing milk yields - and profits.

They're Kevin King of Kingdom Haven Farms at Edgar, Gary Ruegsegger of Maple Ridge Dairy at Stratford and Steve Killian at Blair.

Farm profile

Killian: Steve and Amanda Killian and their three small children have a 60-cow herd of registered and graded-up Holsteins (Dirt-Road Holsteins) and registered Jerseys (Killian Jerseys). These Trempealeau County producers have 35 Jerseys and 25 Holsteins, and have been milking cows for six years on what used to be Amanda's home farm. Formerly, Steve farmed with his brother, Bernie, near Independence. They also have some 70 heifers and some bulls out of their top cows that they intend to sell.

They own 284 acres and rent another 50 and crop 160 acres, growing alfalfa for haylage, corn for silage and chopping oats for heifers. They have additional pasture and buy about half of the grain their herd consumes. The Killians supply the vast share of labor for their operation, occasionally hiring a high school student or Amish friends.

The Killians are unique in that they combine management intensive grazing with a conventional, year-round, full TMR. They're into show cattle (primarily the Jerseys). They've purchased a few high-index Holstein cows and have their first bull contract for AI this year. They flush top cows in both breeds. The "niche" they're pursuing for sustainability in the dairy industry is higher-dollar-end genetics with the goal of selling embryos.

The Jerseys average 20,472 pounds of milk, 4.95 percent fat (1,013 pounds) and 3.81 percent protein (781 pounds). Their Holsteins average 30,712 pounds of milk, 3.81 percent fat (1,170 pounds) and 3.26 percent protein (1,001 pounds).

Ruegsegger: Maple Ridge Dairy in Marathon County is managed by Gary Ruegsegger and his brother-in-law Ken Hein and his father-in-law Phil Hein. Gary has been with this Stratford operation nine years. Through step expansion, the herd has grown from 300 to 1,000 grade Holstein cows (950 milking in a double-16 Germania parlor). The farm employs 16 individuals (in addition to the management trio) to handle cows and 1,500 acres of cropland (900 of alfalfa and 600 of corn). The herd is housed in a six-row freestall facility, with specific areas for pre and post-fresh groups, and three calving packs. Heifer calves are kept on site until four months, at which point they're moved to a custom-raiser, where they'll stay until two months prior to freshening.

This large herd has a 32,000-pound rolling herd average.

King: Brothers Kevin and Mike King married sisters - Linda and June, respectively. The two couples, along with their families, own and manage Kingdom Haven Farms at Edgar. The farm has been in the King family 120 years, and the Kings' father, Aloysius, is still active on the farm, which consists of 2,200 crop acres of corn and hay and 650 cows (575 milking). In addition to family, Kingdom Haven Farms employs seven people. Family together and teamwork are key on this extremely well-managed operation.

About 90 percent of their Holstein cows are registered. The rolling herd average is 28,800.

Cattle are housed in sand-bedded freestalls. A post-fresh group is in their five-row barn on the two-row side. Pens comprise a maternity area. They milk in a double-six parlor and youngstock are raised on the farm. In 2002, this Marathon County farm grew to include a heifer facility, which includes a section for transition cows. This facility has outside feeding and eight rows of stalls.

Steps to Maximize Cow Comfort

Killian: Cows lounge on a bedded pack of sawdust and chopped straw (five inches deep) in a tiestall barn designed for 51 cows. Steve has added PVC pipe to the back end of the stalls to hold bedding in place. He's cut out tiestalls and added a bar up front to increase stall size. Electric trainers are key to keeping stall beds clean. Cattle are rebedded every day and manure constantly pulled off. People are impressed with how clean the cows are.

The barn also has four four-foot fans for tunnel ventilation. Steve wishes there were a few more.

Roughly 10 months of the year, cows freshen on pasture. During winter months, they freshen on a pack. The Killians have invested in a heifer shed, but larger heifers are outside year-round with woods and buildings to break the wind.

Grazing adds tremendously to cow comfort - and health. "The cows are not on concrete 24 hours a day and they're getting exercise," he says. Spring and fall, when it's cooler, the cows might be out on pasture eight hours during the day, but in the heat of the summer, they switch to nighttime grazing. Cows stay inside where it's cooler during daylight hours.

However, the exercise the cattle get out on pasture keeps them fit and aids in getting them bred back. The Killians calve in all of their heifers and sell some for dairy purposes. Steve likes to "see what they're going to be" and get that calf, versus selling them bred.

Ruegsegger: "Sand is the thing," says Gary of their bedding of choice. Freestalls are rebedded once a week, and they'll go in and level the sand in the stalls once during the week, too. Every time they push up cows for milking (three times a day), manure is cleaned out of stalls.

The barn has fans over where the cows recline and misters over where they eat.

Gary maintains that as important as comfortable housing are "good employees" with good animal husbandry skills. They strive at Maple Ridge to "retain good people," he stresses, "who are good with the cows." He thinks good dairy skills are probably more a matter of training than hiring, though.

Their employees "care for dairy cattle," treat the cows right and "want to come to work," says Gary, noting they attract and retain such people (to whom it's important to keep cows comfortable and stress-free) by providing them with a "pleasant work environment."

In addition, they don't do group calving but handle individual cows. The pens are bedded with a combination of sand (for traction) and straw (for a softer cushion).

King: "Sand bedding - that's the big one," says Kevin, noting that dry cows in the fall now are comfortable in pasture lots.

"We tried sand savers, but don't like them," says Kevin, who thinks the cows aren't as comfortable with them. "If the cows aren't happy, it's not good." They re-bed with more sand every week.

A hoof trimmer comes in every week so they can stay ahead of sore feet. And stalls in their second barn are four feet wide for added roominess.

"We also train our guys to be good to the cows. That's a barn full of mothers. Everyone should treat them that way," says Kevin, who feels good husbandry and comfortable cows are different sides of the same coin.

They spray cows in the holding area to keep them cool in the summer. They've put fans over the stalls, as opposed to over the feed area. Kevin admits they "asked everybody" which place for fans would be best and didn't receive any satisfying answers either way. In the end, they made up their own minds, reasoning that "if cows are comfortable lying down, that's where they make milk," says Kevin, figuring they'll get up to eat anyway. But they didn't want to have cows standing to be comfortable (with fans over the feed line). When they're standing, they're not making milk, he reemphasizes.

Feeding for High Production

Killian: For roughly four years, this producer has, as noted, combined grazing with a full TMR, that pretty much stays the same year-round, other than backing out haylage and replacing it with high-quality pasture in the summer. "That's what's unique about us," says Steve, who's achieved impressive production with this hybrid feeding system and hasn't sacrificed any milk by turning his cows out on well-managed pasture.

"We really don't change the (one-group) TMR much," he says. Rather he limits hours spent grazing as the pasture changes in quantity and quality. This time of year, the cows are out grazing about four hours in every 24. He'll back off on about half of the haylage when pasture is at its peak. "That's as far as we'll go," he notes.

They also feed ground dry corn (the basis of their grain mix), five pounds of cottonseed, 2.5 pounds of long hay, and the ration is running at all times between 5.7 and 6.2 percent fat, from different sources. "I keep the energy as high as I can at all times," stresses Steve.

Ruegsegger: Gary says they have no "fixed formula" for haylage and corn silage. Percentages vary as feed availability changes. Right now they're feeding one-third corn silage/two-thirds haylage. He says they're planning, though, on feeding more corn silage as it's an "easier feed to get in a timely manner." "Haylage is so weather-dependent," he complains, noting they're looking at dropping back about 10 percent on haylage and stepping up to 40 percent corn silage/60 percent haylage.

Cows get four pounds of baled hay, wet distillers and five pounds of cottonseed. They also feed different qualities of haylage, chopped straw to maintain fiber mat and beet pulp pellets. In the grain mix is dry corn, ground barley, a little soybean meal, bypass fat and some bypass protein (mainly blood meal).

"Feed consistency is important" for high production, says Gary. "We don't make abrupt changes, and we adhere to feeding schedules strictly. Cows are creatures of habit."

Forages are analyzed every three weeks.

They pick up weigh-backs and give the leftovers to 80 steers. They buy feeders for the purpose. That leftover feed is not given to heifers or dry cows for biosecurity reasons. Twice a day cattle get fresh feed put in front of them. Theirs is a one-group TMR except for an early-lactation ration.

"We really work hard at feeding no mold to our cows," he stresses. "We clean off the top of the bunkers, and the bottom of bales we'll cut off with a chainsaw. Mold throws cows off feed. It's just part of our routine here and everybody on the farm knows that we do not feed mold."

Water is an important ingredient for making a lot of milk. Gary says they scrub waterers out three times a week. "Water intake is important," and access to clean fresh water promotes drinking.

King: "Good forage" and "consistent" feed, says Kevin, who finished fourth-crop the second week of October. His brother, Mike, does 90 percent of the feed mixing and his son, Scott, the remainder. They feel it's important the same person do the TMR mixing as much as possible.

They test feed routinely and make sure they deal with the change in quality accordingly in order to maintain constant high production. They feed 60 to 70 percent haylage to the cows, with the remainder corn silage - no BMR corn, says Kevin (although they do have a silage-specific variety). They tried brown mid-rib corn and didn't like the yield hit. Kevin says it didn't stand as good and "you can't feed it to dry cows." With everything in bunkers, it's hard to separate feed out.

They have 150 steers on the farm and they get the edges and tops of the bunkers. They also get all the weigh-back from the cows. None of that is fed to heifers.

They're heavy on haylage in the ration because, notes Kevin, it's "cheaper to feed." They don't have to buy a lot of protein. Their cows get their protein basically out of the forage. They start first crop at the end of May and try to stay on a 30-day schedule.

What's the Transition Program?

Killian: Though only 38, Steve says he took over decision-making in his home herd in junior high. "I've been milking cows 25 years already and I've done a lot of dry-cow programs," he remarks. He's come to the conclusion that simple is good. He feeds 50/50 or 60/40 (corn silage/haylage) on a DM basis. Key, though, is feeding 2 to 3 times the recommended levels of a custom mineral mix and magnesium oxide. He hasn't had a case of ketosis in three years. He's had one DA in the last two-and-a-half years and that case was a cow that was a week from drying off.

He thinks quite a bit of mineral is "lost" to the cows, by putting it in the TMR and spreading that out in the mangers. Mineral, which is essentially "rock," he notes, tends to settle in water cups, too. If it's only fed to recommended levels, he doesn't think he's "getting enough in them."

Ruegsegger: "Pretty standard," says Gary. They have a dry cow facility. Heifers are in there until three weeks prior to calving. Then they're put on a pre-fresh ration and moved near where they're going to calve.

The ration is important. They use anionic salt to control milk fevers. They monitor urine pH every week.

Cows in the just-fresh group are monitored for 10 days. They have an elevated "vet room" in the pen. Semen and supplies are stored in that room. This makes it handy and easier for the herdsman and assistant herdsman to keep a closer eye on these cows. It's easy to see if they're eating and lying down. That pen fills up to 50 cows.

"We also record milk weights twice a day on that pen," to catch problems early, Gary reports.

He confesses that they do put "problem cows" in there, even though "you're not supposed to." They have a red-banded group of treated cows.

King: They manage far-off dry cows and have a close-up group into which cows are moved 30 days pre-fresh. Then they're moved to a freshening area a week or less prior to freshening. There they're on a manure pack. They start to feed the milking TMR the last week prior to freshening with the close-up dry cow ration at the same time. They feed a one-group TMR. After cows freshen they also get dry hay. Their post-fresh group gets dry hay, too (4 to 5 pounds). Cows are in the post-fresh group a month or less. All the problem cows are in there, too - ones with sore feet or mastitis.

Kevin says his wife and Mike's treat cows - not their milkers. He says his wife "can smell ketosis on a cow," so they like to have her in the parlor once a day. She's always there for the noon milking.

They "temp" cows that look "off" at the 5 a.m. milking.

Again, Kevin emphasizes that they train their help to "take care of the cows" and watch them closely. They use pedometers to check cow activity and take milk weights, which June goes through once a day. If somebody is off feed, "somebody goes and finds them." Everyone "keeps their eyes open."

Keys to High Production

Killian: Genetics are important. Steve even thinks the average genetics in today's cows is so great that if they're managed right, they'll put a lot of milk in the tank.

"Quality forages" are absolutely crucial, says Steve, who puts haylage and corn silage in six 200-foot bags on a base of about eight inches of 1.5 to 2-inch rocks. Getting forage in on time is a challenge for Killians from a labor standpoint. Thus Steve plants 105-day corn that stays green longer; he can put it up later and have good quality. He has 12 acres of "silage corn." As for haylage, he doesn't want to be below 130 RFV, or it "starts coming out of your pocket," says a farmer who'll make 3 or 4 crops of alfalfa a season.

"Grass definitely adds to profitability," he continues. "That's very high quality feed for 4 to 7 months of the year. Grass doesn't impact our production up or down."

Steve says he's had a cow peak at 211 pounds. She was outside on grass with the rest of the cows. In the barn, however, she was eating a "pile" of feed, too.

"Attention to detail and knowing your cows" also makes milk, adds a farmer always willing to put in "extra effort" to pamper cows. For instance, he says he's willing to mix feed as much as he needs to so it's fresh in the summer.

Ruegsegger: Cow comfort and "forage quality," states this north central Wisconsin producer, who shoots for putting up haylage that's around 170 RFV and "at the right moisture." "We really work at that," he says of careful harvest and bunker management. They average three crops of alfalfa a year, but take four if they can get it.

Maintaining condition on cows milking their hearts out is "always a challenge," Gary admits. The nutritionist comes every three weeks and "that's his obligation." "He helps us with that," notes this producer of tweaking the ration.

Intake is what "drives" that, and quality forage drives intake. Cows at Maple Ridge eat a lot of it.

Gary says they do put in some 145 RFV forage. They'll feed 8 to 10 pounds of that to help maintain the fiber mat. First-crop provides the most effective fiber, he says. They'll also feed that 100 percent for dry cow needs.

They had two harvesting "cycles" this year, and next year, they'll put all of first crop in at a later date. It has to be good feed, he stresses of shooting for 35 to 45 percent DM. "That's the most palatable moisture. If it's wetter, they don't like it. If it's drier, it doesn't pack," he remarks.

High production is created in cows early on in life. They have cows mated, working with Genex.

Gary says they have a lot of purchased animals in their herd's genetics. Two years ago was their last step expansion when they added 70 stalls. Eight years ago they started expanding - moving to 270 to 500, where they stayed for a couple years. It's been pretty steady step expansion every two years since then. "We don't adapt technology real quickly. We really study and analyze," says Gary of their more conservative approach.

Two-and-a-half years ago they started pasteurizing waste milk for their calves. They're seen a "dramatic improvement" in calf health and growth over feeding replacer. Gary thinks "everybody" should look seriously at this. "I wish we'd done it sooner," he admits.

King: As noted, good forage, consistent mixing and not forcing cows to eat sub-quality feed.

"We don't breed high production into our cows. We breed for type. We like big-framed cows. We'll make them milk," he reports.

"We don't breed with a ton of milk. We see more benefit from a typier cow, with good udders and feet and legs," he stresses. "A 160-pounds-a-day cow that can't make it to the parlor is not going to make money."

What About 'Profitable Production'?

Killian: Steve admits it's difficult for a producer to determine where the most profitable level of production is, especially when the price of milk goes up or down frequently. What he does know is that when the price drops, "you can't afford to pull things out of the ration." Steve says you might "save a nickel" doing so but "lose a dollar." Even when the squeeze is on, he refrains from knee-jerk cost-saving measures.

While he manages closely on refusals, Steve never feeds any sub-par moldy feed to the cows. For profitability and healthy cows, there needs to be a conscious "commitment" to only put the best quality possible in front of them. "If you don't have any good feed, you need to buy some," he notes.

Profitable production is also the result of "healthy cows," he adds. "A whole lot of milk is wasted if cows are sick," he remarks.

Ruegsegger: Maximizing production from the cows you're milking is the "most economical" gain, rather than adding more cows, Gary explains. He's after "more milk through the parlor" than cows. They can do that without hiring more people; it takes more hands to handle cows.

"Could we do things cheaper and get the same amount of milk?" muses Gary. "Probably. But I don't know what we'd do." He says they pay a "little more" for some of their feedstuffs, but they want "consistent quality feeds."

Maple Ridge Dairy has optimized cow comfort and bettered facilities. "Now where we'll get additional production will be better animals," he discusses of maximizing profitability.

He states, though, that cow comfort is necessary for dairy cattle to "express" genetics for high production. Now that they've optimized cow comfort, they're seeing a slower climb in herd average in the last three years than what they enjoyed in the beginning of the expansion.

As a side note, Gary says they're buying most of their grain. They can buy it cheaper than they can grow it, though that might change as demand for corn for ethanol production strengthens.

King: There needs to be a "balance," states Kevin. While they shoot for high production, it's not at all costs.

"We have a cheap ration," based on "good forage," he reports. "We don't buy milk production. We sell milk."

There's nothing "outlandish" in their TMR, he continues, pointing to standard fare like soybean meal, roasted beans, cottonseed and distillers.

As for feed utilization, his brother Mike "watches close." When it's hot, the cows get fresh feed twice a day. It's close management like that, that contributes to profitability.

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