Lely A5 Next robots boost milk yields by 1,000 litres a day at Leicestershire Farm

Upgrading to the latest-generation Lely A5 Next robots has helped one Leicestershire dairy boost milk output by five litres/cow and reduce milking failures. 

Steve Pierce runs a 330-acre mixed farm alongside his wife, Emily, their children, Huw and Lottie, and his mother, Hilary. 

The family had dispersed their dairy herd in 2016 when the milk price crashed to 19p/litre and diversified into beef and sheep.

But it was always Steve’s dream to return to milking with robots, and within seven years of dispersing his herd, he went back into milk at Foston Lodge Farm in Leicestershire. 

The dream became a reality with the installation of a new cubicle shed for 128 cows and two Lely A5 Next Astronaut robots.

Foston Lodge has been one of two validation farms in the Midlands trialling the new Lely A5 Next robots.

About the upgrades

The Lely A5 Next upgrades include a completely new ‘brain’, allowing remote software updates and laying the groundwork for remote servicing.

Not only do the upgrades prolong the life expectancy and stabilise depreciation of the robots, but they have also eliminated the repetitive task of changing milk filters twice daily. 

The installation of the upgrades to the two machines, which a Lely technician carried out last November, took less than a day. 

The process was completed in stages to allow cows to continue being milked throughout.

The upgrade involved fitting a GCBCorePro “brain”, AOS-2 software and a new Teat Detection 2 + System (TDS2+) using laser and camera technology for better visibility and accuracy.

“The cows are more comfortable, and there is less arm kicking. The number of refusals we were getting in one day now only happens in a fortnight,” explains Steve. 

The pretreatment optimiser adapts brushing to each quarter to prevent bimodal milking. This has contributed to improved milk speed and yield.

Milking speed has increased from 2.54kg/minute to 3.1kg/minute, notes Andy Wilson from Lely Center Midlands, who has overseen the validation study. 

Furthermore, milk yield has jumped from 38kg to 42kg per cow, equating to an extra 1,000 litres daily. This has surpassed the family’s expectations.

“With 100 cows, we are producing the same amount of milk as 140 cows in the old 18/36 swingover parlour,” comments Steve, who has further lowered labour requirements.

Previously, the former herd was managed by two staff members, Steve and his father, Wyn, who sadly passed away before the unit was completed. 

The whole farming enterprise is now run by the five family members, with the addition of Lely’s automatic feed pusher and Lely Discovery slurry collector further automating tasks inside the dairy shed.  

Upgrades reduce downtime

Callouts and alerts have dropped significantly thanks to improvements in the robot arm, which reduces claw dislodgements and interruptions. “You can go to bed and stay there,” says Steve.

One standout feature for Hilary is the new fully automatic milk filter. The system replaces traditional filter socks with a stainless-steel membrane and back-flush cleaning.

The A5 Next will be available in the UK from July 2025. Existing A5 users can upgrade to the new software from next June, although the automatic milk filter is not compatible with sand-bedded systems.

For more information, contact Lely Midlands on info-sta@lelycenter.com

Performance Gains

• Milk yield has risen from 38kg to 42kg per cow/day.
• Milking speed has improved from 2.54kg/minute to 3.1kg/minute.
• Overall milk output has increased by 1,000 litres/day.
• The automatic milk filter has reduced labour requirements.

Foston Farm facts:

·       Farming 330 acres; 250 of which are owned, the rest is rented

·       Milking 95 cows; 110 in the herd and 80 youngstock

·       Supplying Meadow Foods

·       Yielding 43kg daily at 3.68% butterfat and 3.38% protein

·       Somatic cell count: 118,000 cells/ml

·       Bactoscan: 12

·       270 Texel cross Mule ewes

·       Selling 100 Angus cross dairy store cattle.