Marshfield Farm

Automated milking has translated into better yields, lower labour requirements and greater flexibility at the home of Marshfield Farm ice cream near Bath.

Robots have proved the perfect fit at Marshfield Farm in Wiltshire, optimising the volume of milk going into their ice cream business and creating the high welfare system their customers demand.

At the start of the year, the Hawking family said goodbye to their 30:60 swingover, using a Farming Equipment and Technology Fund grant to help replace it with four Lely A5 Astronaut milking robots (see back page). In just a few months, yields have climbed by 17%, putting them on track to achieve their 12,000 litre per cow target by the end of the year. Labour requirements have also reduced by 1.5 units, whilst flexibility and work life balance have improved.

The farm business has undergone significant change in recent years, instigated by the loss of their organic milk contract in 2023. Faced with a decision around how to move the business forward, the family decided to change to conventional production and focus on regenerative farming which would benefit soils, biodiversity and forage yields, and suit the image of their national ice cream brand.  Grazing would continue to be a priority, particularly considering feedback from a customer survey which put welfare second after product quality. 

It was Rory Hawking - the youngest of the family at 25 years old - that pushed for the conversion to automated milking, having seen the welfare and production benefits at Stowell Farms in Pewsey. 

His father Will - who initiated the diversification into ice cream in 1988 - and Herd Manager, James Smith were initially against it due to “horror stories” around being called out by the robots in the middle of the night. However, they were quick to change their minds after speaking to farmers that had installed Lely robots. James was also struggling with pain in his shoulder from 25 years’ of repetitive milking. He recognised automation would also benefit efficiencies.

“We’re all about embracing technology… and we’d got to the point where the cows were giving 10,000 litres on twice a day and they needed milking three times a day but no-one had the inclination to do that,” he explains.

Yields

When the robots were installed, milking visits quickly increased to an average 3.3 per cow per day. This has driven a yield increase, with cows averaging 42 litres per cow per day in April versus 36 litres at the same time last year. Quality has remained the same. 

The uplift in milk volume - which is needed to produce high volumes of ice cream - has reduced the litres of milk needed to be bought-in for processing, which has benefited efficiencies. Increased milking frequency has also helped lower mastitis from 18 cases per 100 cows to eight case per 100 cows. James says this has been aided by milk conductivity readings and real time health alerts through the robots. This means cows can be treated earlier with non steroidal anti-inflammatories and Udder Mint, reducing the need for antibiotics. 

James had already witnessed the benefit of monitoring individual cows having used Lely NEDAP collars to track rumination and bulling for seven years. “You can be far more proactive rather than reactive,” he explains.

James says cows are much more able to express their natural behaviour which benefits welfare, whilst his own work life balance has improved dramatically. “My alarm clock goes off at 0530 not 0345 which is huge. Milking cows twice a day just takes its toll, and the tiredness. Now it’s a much more relaxed way of working.”

Labour

Now, one person can do the cows, rather than two to three. James and “half a Rory” now work on the dairy. Two full time tractor drivers do the feeding and bed up the loose housing, but they are no longer needed in the afternoon to push up cows or bed up cubicles. This translates into a saving of 1.5 labour units, with staff redistributed onto the ice cream side of the business. The amount of time doing jobs has also reduced, meaning one person can now work 1.5 hours on a Sunday afternoon versus two people spending 7.5 hours.

Rory says the flexibility the robots provide is a big plus, allowing him to spend more time on ice cream or forage harvesting when needed. “We’ve got more time to tidy up and keep the yard clean,” he adds. “We’ve got customers coming round twice a week, and it’s great to be able to show that the cows have choice and it’s better for welfare.”

Cows are yet to be grazed on the robot system, but will be turned out in the summer to meet RSPCA accreditation standards to graze for a minimum of four hours a day for 120 days. The plan is to give them the free choice of whether to go out or not.

BOX: Farm Facts

•   Will Hawking farms with son Rory and father, Tim.

•   1,200 acres farmer including 400 acres of cereals used for grain and 80 acres of maize. The rest is grass.

•   225 Holstein Friesians milked through four Lely A5 Astronauts.

•   Calving 1 November to end May.

•   10,100 litres a cow a year at 4.5% fat and 3.4% protein for the 12 months to march (robots installed start of 2025). On track to achieve 12,000 litres a cow a year.

•   3.3 average robot visits per cow per day.

•   Four Lely Juno robots pushing up feed 23 hours a day. The first was installed eight years ago with the number increased in response to increased feed intakes.

•   3,300 litres milk from forage per cow per year (pre robots).

•   Somatic cell counts of 155,000 cells/ml and Bactoscans of 17.

•   Top 40% put to sexed dairy semen with the remained to British Blue or Aberdeen Angus. Beef sold to Buitelaar at 4-5 weeks old.

•   75% of milk used to make own ice cream with the rest sold seasonally to Muller.

•   Producing seven million litres of ice cream (including sorbets and plant-based products) per year under the Marshfield Farm brand which is sold nationally.

 

Ongoing support eases set-up process

From advising on how to integrate robots into existing buildings to “hand holding” through the start-up process, the team at Lely Center Yeovil has made the conversion to robots “less stressful” according to Rory Hawking at Marshfield Farm.

“The knowledge that is there is extensive,” he says. “Beth Medlicott from Farm Management Support has helped with everything from how to group cows; to how starter week works; to changing the setting on Horizon in a gradual process; to handing it over to us. We couldn’t have done it without Beth. She’s been brilliant.”

Project Coordinator, Alistair Cumings mapped the existing buildings and advised on how to modify the two sheds to accommodate the robots. This involved extending both buildings and relocating some cubicles to increase cross overs and optimise cow flow.

“Alistair was very good,” Rory says. “His knowledge and communication was really good. It’s the way Lely holds both of your hands through the set-up.”

Beth supported the team with the start-up process, which included working with them to establish their performance goals and setting targets. At Marshfield Farm, this focused around achieving 12,000 litres a cow a year, reducing labour and improving efficiencies. Beth was also on farm for four days in start-up week to ensure a smooth transition.

She adds: “The support we offer is ongoing. Six to eight weeks in we do a post start-up review to see how things are going and whether they’re achieving their goals. We also carry out a six monthly review with all customers to discuss their targets.”

To improve efficiencies and maximise production from high yielders at Marshfield Farm, Beth has been gradually altering the settings for maximum milking time (units on time) and box time (total time in the robot) per cow.

“We are gradually reducing milking times - which impacts on box time -  so as to create free time in the robot for other cows to visit. In doing so, we’re optimising capacity and providing more timid cows with the opportunity to visit,” she explains. “It’s a balance so all cows have the opportunity to visit and give the best amount of milk in the time available.”

Beth stresses that settings changes for these parameters should only be carried out under the guidance of Farm Management Support and will vary from farm-to-farm.

 Get the inside scoop!

The Hawking family are hosting a Lely Center Yeovil open day at Marshfield Farm on Thursday 4th September 2025. See the Astronauts and Junos in action, find out how the high welfare, robotic system complements their Marshfield Ice cream business and sample a scoop!