Fullwood Merlin – the automated milking system for today`s farmer

The Fullwood Merlin
– total control for
maximum profit
Inverter control of
vacuum pumping and
compressed air.
Minimise electricity
consumption.
Ice bank cooling
and tube coolers –
best milk quality, lowest
cooling costs. Buffer
tanks – maximise
available milking
time in Merlin.
Crystal soware –
think you know some
of your cows – Crystal
knows them all.
The Fullwood Merlin
By Appointment To
Her Majesty The Queen
Dairy Equipment Manufacturers
Fullwood Limited Ellesmere
Heat recovery
system – minimise
water heating costs.
Total feeding
system control.
Linked with out of
parlour feeders.
Up to four feed
types.
Highest capacity AMS on the market
Grazing gate –
controlled by Merlin
to maximise profit
from grass.
Crysta Act+
pedometer – total
management
of breeding and
heat detection.
4QC and Crysta Lab
– total management
of rumen and
udder health.
Fullwood Merlin –
the automated
milking system for
today’s farmer.
Best for you and
your dairy farm
This complete solution gives total control over four of the
main input costs on any dairy farm – energy, feed, health
and breeding. Controlling costs and increasing yields
through focus on animal health will result in maximum
profit for any Fullwood Merlin farmer.
Fullwood Limited
Grange Road
Ellesmere
Shropshire
SY12 9DF
T. +44 (0)1691 627391
F. +44 (0)1691 627361
sales@fullwood.com
www.fullwood.com
Fullwood and the farmer
Contents
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“At Fullwood we have an
impressive history of helping
the dairy farmer benefit from
advanced milking methods.
From the company’s earliest
days we have had a philosophy
of developing market sector
innovation bringing world
leading technological
advancements to the dairy
industry.”
/ Introduction from David O’Hare
/ An automated milking system or automation in a conventional system?
/ The Merlin Robot comes with advanced features and an impressive pedigree
/ Willem Van der Horst – an overall 23% increase in yield
/ A more intelligent way to run a modern, progressive dairy farm
/ Rod MacBean – 35 years+ and still a Fullwood farmer
/ Crysta Lab – real-time milk component analyser
/ A cooling system designed to meet the demands of robotic milking
/ Herman D’Hauwe – 15,000 litres in a 300 day cycle
/ In their own words – what some Fullwood farmers have to say about Merlin
/ Our dealers are as reliable and user friendly as the Merlin robot itself
/ Servicing Scheme / Technical specifications
/ The Fullwood Merlin – total control for maximum profit
/David O’Hare
Chief Executive
/Cover image
The Van der Horst family
were the first to install
a Merlin robot in the
Netherlands in 1997
Since that time we have been continually improving and
developing our products, to make sure that we are at the
forefront of modern milking technology. The result of continual
innovation and improvement can be seen in our new Fullwood
Merlin robot. We have developed the latest generation of
the Merlin automated milking system, by listening to feedback
from our customers and dealers. By responding to their
comments and observations, we have produced a flagship
model that offers a range of important new benefits for both
the farmer and the dairy herd.
Fullwood and the farmer – Introduction from David O’Hare Page 03
An automated milking
system or automation in
a conventional milking
system?
?
…the best advice is to take a long hard look at all possibilities
and decide whether the introduction and operation of robots
is right for your business, your lifestyle and your future.
There comes a time for many of today’s modern
dairy farms when the issue of automated milking
comes up for consideration. The reasons are many
and varied, for example the necessity to cope with
a growing herd, the opportunity to reduce labour
costs, the desire to improve the welfare and
management of the cows, the need to reduce time
spent in the milking parlour or the continual drive
to produce consistently high quality milk.
Whatever the reasons for considering robotic
milking, the best advice is to take a long hard look at
the numbers and decide whether the introduction
and operation of robots is viable. However, it is
equally important to understand all of the very real
benefits that will come from an automated milking
system. In many cases there is a significant increase
in yield, although the nature of the increase
obviously varies from farm to farm. There is also
the opportunity, thanks to the latest technology, to
precisely identify any cow in need of special
aention, enabling the early detection of problem
conditions such as mastitis. The ability to achieve
higher feed efficiency contributes to overall cost
control by reducing feed costs. And the cow’s ability
to be in control of her visits to the robot reduces
the levels of stress leading to healthier and more
productive animals.
and sensor technology in conventional milking
parlours. However, time not spent milking but
managing cows is where robotic milking wins. For
today’s farmer the dramatic reduction in milking
time is one of the biggest advantages of installing
robots, as it creates more of the most precious
commodity of all, namely time.
Itis important to understandallof thevery
real benefitsthat comefrom anautomated
milking system; in many cases there is a
significant increase in yield.
The extra time can be used in so many ways, whether
that is to aend to day-to-day tasks on the farm,
improve the general management of the farm, make
plans for the future, or to have a beer work-life
balance and to spend more quality time with the
family. The transition from conventional milking to
robotic milking can be quite a challenge, but the
rewards are always worth it.
Whether you farm 30 or 10,000 cows, Fullwood have
an automated solution for your needs.
Just remember, many of the advantages of robotic
milking systems can be achieved using automation
Fullwood and the farmer – Making the right choice Page 05
The Merlin robot comes
with advanced features and
an impressive pedigree
Stress
The Fullwood Merlin gives you:
–– The fastest aachment speed of any AMS on the market
–– The most advanced sensor technology of any AMS
–– Crystal Herd Management System – the power to manage
–– Premium quality – full stainless steel and built to last
–– Future-proof technology – security of investment with
low running costs
Productivity
The decision to install an automated milking system isn’t one
you’ll take lightly. And as we offer a complete range of systems
from rotary, herringbone and parallel milking parlours through
to the most advanced robots, we will always provide the best
possible advice to meet your personal requirements. To help
you evaluate the benefits of installing robotic milking we will
assess every aspect of your operation and your plans for
the future, working with you to reach the best conclusion for
your farm.
An impressive history and heritage
At Fullwood we were in at the beginning of robotic
milking with the first – generation Merlin robot
introduced in 1996. Since then we have improved
and upgraded Merlin in line with feedback from
our customers and dealers and by incorporating
advances in technology. Over the years we have
developed 6 generations of Merlin, and as testament
to our ‘future-proof’ commitment, all six of these
generations will work happily together on one farm
and on one computer. We currently have Merlin
installed on many farms throughout Europe, their
performanceandreliabilityleadingtofarmersadding
a second, third and as many as 14 Merlin robots.
Merlin works around the clock, so you don’t have to.
The most important benefit that the Merlin robot
offers is that it enables the cows to choose to be
milked twenty four hours a day, without you or your
team being involved in the milking process. This
means you’re not tied to set milking times regardless
of other pressing duties on the farm, family
responsibilities and your social commitments. Put
simply, a Merlin robot gives you back your life.
Advantages for you and your cows
The advantages for the farmer of robotic milking
don’t stop at being released from a rigid and timeconsuming milking regime. There is also the ability
to identify any cow in need of aention, control
overheads by reducing feed costs and keep labour
costs down. The cows also benefit in a number of
ways; they have the freedom to choose when to be
milked, there’s no more standing for long periods in
collecting yards and bully cows no longer intimidate
the quieter animals. The increased frequency,
typically 2.7 times a day, can result in improved
udder health and increased comfort for the cow.
Perfect feed management and individually tailored
diets, with a choice of up to 4 feed types further
enhance health and productivity. All of which reduces
the cows’ stress levels leading to a healthier and
more productive dairy herd.
Fullwood and the farmer – Setting out the Benefits Page 07
1. Crysta Act+ pedometer
2. Stainless steel feed dispenser
3. Robust Merlin gate
4. Merlin laser
Cow movement in and out of
Fullwood Merlin robot.
3
1
4
2
Planning
Installation
Comprehensive planning process
Fullwood’s designers use the latest technology to
plan every Merlin installation.
Total reliability
Every Merlin is constructed of heavy duty, high
quality stainless steel. You can expect total
reliability; repetition and 24 hour working are not
a problem for Merlin.
Free traffic is Fullwood’s system of choice,
in conjunction with out of parlour feeders.
Management of availability of feed is key
to maximising the productivity of Merlin.
The combination of free-flow cow traffic, easy entry
and exit without the use of force reduces stress
on the cow. Experience has shown that left to suit
themselves, cows will enter the unit to be milked
almost any time of the day or night. Merlin
encourages the cow to enter by an enticement
of feed. Free traffic is Fullwood’s system of
choice, in conjunction with out of parlour feeders,
management of availability of feed is key to
maximising the productivity of Merlin. However, if
your choice is to have a forced traffic system,
Merlin can manage multiple selection gates and
multiple route selections all at the click of a mouse.
Identification
Reliable identification & heat detection
The identification system operated by Merlin allows
theuseofeartags,necktranspondersorpedometers
as used in Fullwood parlours throughout the world
(more information on pages 12/13).
During Milking
Advanced sensor technology
When the cow enters the system for the first time
her teats are scanned and their positions stored as
3D co-ordinates.The laser updates co-ordinates
every milking to take account of physiological
changes e.g. differences in the amount of milk in
the udder. Milk tubes retract within the robotic arm
keeping length to a minimum, dramatically reducing
the chance of entanglement damage caused from
the cow standing on tubes. This in turn reduces risk
of ‘call outs’. The static laser has no moving external
parts and no service requirement.
When a cow is identified Merlin decides if she is
eligible to be milked or not. The general rule applied
is that the cow should have produced 7 litres
(default setting) of milk before she is milked, this
amount is adjustable and is based on her current
performance. If a cow returns too soon to the unit
she will be rejected and let out.
Fast attachment
The new arm creates less wear on the main pivot
points, and also features improved take-off
cylinders and new vacuum shut-off valves for faster,
yet gentle, teat cup attachment and removal.The
re-designed arm also provides improved ergonomics,
giving a greater range of reach for improved teat
cup alignment, especially for cows with smaller and
irregularly shaped udders.
Improved take-off cylinders and new vacuum
shut-off valves for faster, yet gentle, teat cup
aachment and removal.
The new design also provides better protection to
therobot’s internalcomponentsforgreaterreliability
and longevity.
Total feeding regime
When the cow has been identified and is due to be
milked feed is dispensed. Merlin incorporates two
feed dispensers as standard with the option of a
third feed and potential for a liquid or mineral feed
dispenser.
High capacity
Merlin’s capacity is recognised as being the best
in the industry. However, capacity varies
depending on the farm regime. Influencing
factors are: herd size / production per cow /
milking speed per cow / layout design and cow
traffic / grazing and feed regimes / cleaning time
of bulk tank and Merlin / calving profile
of herd / nutrition.
Daily production per Merlin in excess of
2500 litres per day is not unusual, however
2000-2200 litres per day is more common.
Post Milking
High speed cleaning programme
The teat cleaning rollers are sanitised with water
and disinfectant after every cow. The teat cups are
also sanitised inside and out after every milking. A
boiling water main clean takes place every 8 hours
selecting a dosage of either acid or alkaline.
Fullwood are recognised as having the fastest
cleaning programme on the market with total
cleaning times as low as 8 minutes.
Fullwood and the farmer – Setting out the Benefits Page 09
The Van der Horsts have three
cows, within their herd, each of
which has passed the magical
100,000 litre mark.
/Willem Van der Horst
Cothen, Netherlands
The family is one of
140 farms that own the
Delta Milk Cooperative,
founded in January 2011.
“We installed the first of our
Merlin robots fifteen years
ago, and they’ve yielded
impressive results eversince.”
Willem and Co stand proudly
in front of their purpose-built
dairy operation.
+23%
There are few farmers who can genuinely claim to
have been pioneers in the field of robotic milking, but
that accolade certainly goes to the Van der Horst
family. It was in 1997 that they had the courage of
their convictions to install the first Merlin robot in
the Netherlands. It’s certainly not a year they will
forget as it was also the 25th wedding anniversary
of Co Van der Horst and his wife Corry.
Clearly convinced that they had taken the right
decision, the family installed a second Merlin the
following year. Aer a decade of dedicated and
profitable service, the original Merlins were
replaced by two later models, a testimony to the
performance of their robotic milking operation.
The results speak for themselves.
They have achieved a 23% increase in yield, when
compared to their earlier parlour and they are
producing 1.3m litres of milk a year from their dairy
farm. And as if that isn’t impressive enough, the Van
der Horsts have three cows each of which has
passed the magical 100,000 litres mark. As Willem
put it, “I was hardly out of school when we installed
our first Merlin robot and the benefits have been
adding up ever since”.
Fullwood and the farmer – Willem Van der Horst Page 11
PO
OBS
ER
O
YS
IS
AU T
O
-C
If an automatic milking system makes sense for your dairy farm,
it can have a noticeably positive effect on your working and
family life. It will enable you to use your time more wisely thanks
to the built-in intelligence provided by the computer soware
technology.
In the case of the Merlin robot we have developed our own
bespoke herd management soware called Crystal. The
soware makes it possible for a comprehensive range of tasks
to be carried out automatically. These cover milking, feeding,
weighing, separation, health and fertility issues.
The added bonus of being able to collect data on all of these
areas is that it can be imported and exported into other
management programmes and related organisations, for
example milk recording and cale movement agencies. It also
provides you with a single source for efficient record keeping
as well as a 24/7 online helpline to provide assistance.
L
–– It will save you time. Accurate analysis of every cow in your
herd will prompt the appropriate automatic actions.
–– It will help increase yield. Ensuring each cow has a tailored
feed regime will maximise yield across the herd.
–– It will maximise profit on your farm. The combination of
precision feeding to increase yield and reduce waste,
automatic herd management controls and early alerts of
any health issues to allow quick intervention, reduced vets
bills and maintained milk levels will shrink costs, grow
revenues and ultimately maximise your profit.
AN
A
Why choose Crystal?
R
NT
OL
N
RE
RT
G
IN
TIO
VA
A more intelligent
way to run a modern,
progressive dairy farm
Crystal – Precision Herd Management
Neck transponders or ear tags are also available.
Crystal is the practical and easy-to-use herd
management soware that fully automates the
four key steps of successful dairy management:
1. Observation of the herd to monitor both milk
yield and quality and animal health.
2. Analysis of yield, activity, blood, conductivity,
weight, temperature and feed intake.
3. Automatic Control based on the analysis, the
animals can be automatically controlled
accordingly. For example changes to feed regime
or separated for aention.
4. Reporting provides the farmer and other
interested parties with detailed reports on the
herd as a whole and individual animals.
Once the cow has entered the Merlin robot and has
been identified, the system can detect whether she
is ready to be milked or not and will automatically
commence milking or open the gate to release her.
If she is to be milked, it is during this phase that
further observation can take place through the links
between the sensors in the milk meters and the
Crystal soware.
1. Observation
Pedometers.TheFullwoodCrystaAct+pedometeris
a proven tool for accurately measuring the activity
of each individual animal. Research has shown that
cows in oestrus can be up to seven times more
active than normal. The Crystal soware monitors
activity and accurately determines the breeding
status of each cow. This management tool enables
the farmer to make informed decisions concerning
all aspects of health and fertility within the herd.
Further functionality of the pedometer allows the
measurement of lying time and the number of
lying bouts. The ability to measure restlessness or
long periods standing can help detect cows in
need of aention.
4QC - quarter conductivity sensing. Changes in the
electrical conductivity properties of milk can
provide a valuable early warning of the likelihood of
intra-mammary infection (mastitis), particularly
when combined with reductions in milk yield. Merlin
measures the conductivity of milk throughout the
milking from each individual teat, to pinpoint
problem quarters. Independent tests have shown
that 4QC can reliably detect milk from quarters
infected with major pathogens and/or visible signs
of mastitis to a level comparable with or beer
than human milkers.
Sensing milk flow per quarter. Sensors monitor each
individual quarter’s milkflowand initiate removal of
each teat cup when the quarter has finished milking.
Thisavoidsunnecessaryover-milking.Aerthelast
teat cup has been removed each teat is sprayed
individually with disinfectant according to the cow’s
coordinates. This ensures a more effective coverage.
The robotic arm then retracts and the cow is now
ready to leave the robot.
Fullwood and the farmer – Crystal Herd Management Page 13
1. Segregation gate
2. Out of parlour feeders
3. Milk separation unit
Integrated Herd
Management for
maximum profit
1
Crystal analyses and combines all the sensor
information with parameters set in the system by
the end user. By making detailed comparisons
between actual performance and health in relation
to the previous ten day average, the system can
take automatic actions to adapt the feed regime
in Merlin or at the out of parlour feed station,
segregate the cow for attention or reject milk based
on likelihood of mastitis.
Animal observation and analysis is the first step
but using this information to take critical action is
the important second step in herd management.
Events such as oestrus, identified through analysis
of the data from the Crysta Act+ Pedometer, can
be very simply added to the cow’s unique record in
just a couple of mouse clicks (Fig. A).
This quick and easy method can also be used to
update the record of a whole group or to separate
individual cows or groups for attention.
3. Automatic Control
Crystal can fully automate processes in response to
a combination of events. Depending on parameters
and conditions set by the farmer, the system carries
out the appropriate actions fully automatically.
Smart Selection Gates for Cow Segregation.
Fullwood segregation systems enable individual
cows to be separated from the herd or the whole
herd to be divided into different groups. These
instructions can be made by Merlin or the user.
The user has the scope to make segregation
instructions on a one-time or periodic basis many
days in advance of their implementation.
Segregation determined by Merlin is used for:
– Separating cows into groups for feeding or grazing
– Selecting cows for attention
– Ensuring cows not milked return to Merlin
Feeding. The system also allows the integration of
feeding in Merlin and/or an outside feed station.
It offers the user the option of restricting access to
the outside feed station in favour of a visit to the
milking station to receive its programmed feed.
This function contributes to labour efficiency, a
costly resource on the modern dairy farm.
Milk Separation. Using information from the 4QC
(and/or Crysta Lab), Crystal enables Merlin to
automatically reject milk from animals likely to be
mastitic and/or which is abnormal in appearance.
The farmer can activate milk separation e.g. for
rejection of colostrum. Multiple robots can be
linked to one separation unit.
Weighing. Crystal can accommodate cattle
weighing within its program. When leaving Merlin
the cow is identified at a convenient location within
the exit passage and is weighed immediately with
minimum disruption to cow-flow.The Fullwood weigh
crate can be incorporated with cow segregation.
The cow is diverted into the programmed location
upon its exit from the weighing station.
3
Fig. B
Fig. A
2. Analysis
2
Crystal gives the user an easy to use planning
tool to carry out specific actions for individual
animals, groups or the whole herd based on
all the available analysis.
4. Reporting
So how is all this information presented to the user?
Crystal opens with a user defined list of important
attention and action lists. The very first mouse click
in the morning informs the farm manager about
the performance of the whole herd, including an
overview of which groups within the herd are
responsible for performance deviations (Fig. B).
Fig. C
Eachsubsequentclickpresentsdetailedgraphical
information of individual animals requiring attention.
It provides the opportunity to analyse the cause of
deviations. For example, lactation performance is
presented in clear graphs including agenda events.
See the obvious oestrus cycle in the green activity
graph (Fig. C).
Last ten days’ graphs present the health and
production profile of an animal. Note the clear red
conductivity graph alerting udder problems at an
early stage before the milk yield and activity drops
down in the following milking (Fig . D).
Fig. D
Fullwood and the farmer – Crystal Herd Management Page 15
/Rod MacBean
Brockhurst Farm,
Shropshire
Rod is the fourth generation
of his family to run the
Brockhurst farm and he is
looking forward to his son
becoming the fih.
The MacBeans have a strong
dairy farming tradition and
Rod is the latest generation
to enjoy a long-standing
relationship with Fullwood.
“We’ve been a Fullwood
farm for over 35 years and
by choosing Merlin we’re
going to stay that way.”
Happy families. Rod shares
a moment on the farm with
his son Jonathan.
+
35yrs
The Brockhurst farm is no stranger to Fullwood. It
was back in 1979 that they installed a 5:10 Fullwood
Herringbone Parlour Pack, and apart from standard
maintenance it has only needed the minimum
aention – serving above and beyond the call of duty.
Although his new milking unit has only been up and
running for a relatively short period of time, he has
increased his herd from seventy to one hundred
and twenty cows, with yields up by 4.2 litres per cow
and feed rate 1kg less per cow, per day.
When Rod took over the farm in 2003 he took a
number of key decisions to secure the farm’s future.
Then in 2010 he decided the time was right for a
complete modernisation. He was determined to
create the very best working conditions for himself,
his team and his growing dairy herd. As part of the
modernisation programme, Rod decided to invest
in two Fullwood Merlin robotic milking systems.
Rod’s modernisation of his farm is best summed up
in his own words. “The farm has had exceptional
service from its Herringbone parlour for over 35
years and I believe that the Merlin robots will serve
us equally well in the future.”
Fullwood and the farmer – Rod MacBean Page 17
Crysta Lab – Real-time
milk component analyser
Crysta Lab is an innovative real-time milk component analyser
that measures fat, protein, lactose and blood. It analyses the
milk as it flows through the in-line unit and continually collects
vital data relating to each individual cow. Decisions can then
be made in the knowledge that the information is up-to-theminute allowing milk production to be improved through early
identification of feeding and health problems.
So how does it work?
By using Buer Fat: Measuring the protein ratio
ensures, early detection of metabolic disorders such
as Ketosis and SARA (Sub Acute Ruminal Acidosis).
Easy identification of cows in negative energy
balance in early lactation allows timely intervention
to quickly return these cows to their optimum
performance.
Lactose measurement in conjunction with
conductivity sensing provides an excellent
detection system for mastitis. Crysta Lab and 4QC
can typically detect the onset of mastitis 36 to
48 hours before clinical symptoms are presented.
Early intervention allows these cows to be treated
without antibiotic use or significant yield loss,
ensuring optimum productivity. Crysta Lab is
calibrated to detect blood content in milk in
accordance with Annex C of ISO 20966. Alarm levels
and reports can be customised to suit individual
management needs.
Page 18 Fullwood and the farmer – Crysta Lab
Key features of Crysta Lab
–– Real-time data
–– Accurate trend analysis of milk
components
–– Feed management and control
(fat control through feeding)
–– Improved animal health (early
detection of SARA, Mastitis, Ketosis)
–– Zero maintenance
–– In-line cleaning
–– Clean technology – no reagents
required
Crysta Lab will increase your profits
through identification of health issues
allowing early intervention, reduced
costs and improved yields.
A cooling system designed
to meet the demands of
robotic milking
24 / 7/365
Our sister company Packo has developed a range of cooling
tanks specifically for robotic milking. Packo’s advanced
technology ice bank tanks ensure rapid and intensive cooling
without freezing the milk and allow use of off-peak electricity.
Direct expansion tanks for use with Merlin are fied
with small cooling units which require a lower startup current resulting in less power requirement.
Each DX AMS tank is equipped with the So Start
Cooling (SSC) system. SSC functions independently
of the robot and reacts to the quantity of milk
present in the tank ensuring gentle cooling and
avoiding the risk of milk freezing.
Why special tanks are needed
Contrary to traditional milking with production peaks
in the morning and evening, robotic milking involves
the cows being milked constantly throughout a 24
hour day resulting in small quantities of milk being
cooled at a time. Both ice bank tanks and direct
expansion are offered for use with Merlin.
The Advantages are clear:
–– Continuous milking no disturbance
to milking rhythm
–– Milking independent of main milk
tank cleaning
–– Automatic cleaning with detergents
ensuring efficient cleaning
–– Milk buyer can collect at any time
–– Additional robots can be added
The Packo buffer tank
Installing a Packo buffer tank between the robot and
themaincoolingtankensuresthatMerlinstand-still
times, when the main cooling tank is emptied or
cleaned, is kept to an absolute minimum.
Fullwood and the farmer – Cooling Systems Page 19
As well as adopting the most
advanced welfare procedures
Herman produces specially
prepared bedding from straw
grown on farm.
/Herman D’Hauwe
Sint-Lievens-Houtem,
Belgium
The farm is both dairy and
arable with the 1.1 million
litres annual milk output
being used for yoghurt and
milk production.
“I’ve always firmly believed,
that if we look after our cows
they will also look after us.”
Herman and his wife Chantal,
share some relaxation time
awayfromtheirbusyschedule.
15,000ltrs
Herman D’Hauwe is the eighth generation of his
family to run the farm. He took over the 35 cows and
30 hectares of farmland, from his father, around
twenty years ago. With that kind of history his
dedication to his dairy herd’s welfare comes as
no surprise.
And his belief in caring for his cows has resulted in
a health record that’s second to none. Always
someone to plan for the future Herman built a
succession of new barns, increased his herd to 60
cows and kept up to date on the development of
robots. When he decided the time was right he
installed his first Fullwood Merlin robot and a year
later, to support his purchase of a second farm,
he installed his second Merlin. As well as adopting
the most advanced welfare procedures Herman
produces specially prepared bedding from straw
grown on farm, which reduces sores and creates
beer activity and healthier animals. He also grows
grass and maize to produce his own high quality
feed. As a result Herman is rewarded with excellent
yields, that in the case of one top performing cow
is as high as 15,000 litres in a 300 day cycle.
Asfar astherest oftheherd of110cows isconcerned
he achieves an impressive average of 10,900 litres
per cow. Herman sums it all up in a few telling words,
“nothing’s too good for our cows, it’s as simple as that”.
Fullwood and the farmer – Herman D’Hauwe Page 21
/ In their own words
What some of the
Fullwood farmers have
to say about Merlin
“The Holzrichters gave the matter a great deal of
consideration before deciding on a Fullwood Merlin.
However, it was the clear benefits it offered that won
them over in the end.“The technology is robust and
mature and I can expand the system quite easily.”
Markus Holzrichter
“The primary reason for installing the robots was to
modernise the farm’s milking facilities and to plan for
Stephen’s long-term future in the industry. Increased
yields, being less reliant on outside labour as well as
a more relaxed and flexible lifestyle for us have been
added bonuses.” John & Stephen Brisbane
“The Merlin robot has been absolutely critical to our
success. It is 100% reliable, and apart from regular
service visits from our Fullwood service technician, no
other help is required to provide stress-free milking
24 hours a day.” Michael Shadrick
Our dealers are as reliable
and user friendly as the
Merlin robot itself
We appreciate the need for reliability and with this in mind
Fullwood offer an approved maintenance plan developed to
ensure that Fullwood milking equipment consistently satisfies
the requirements of the highest standards.
Fullwood specialist Merlin dealers will carry out
a quarterly in depth service under the Fullcare
scheme and offer 24 hour breakdown cover. All our
Merlin dealers are experienced milking machine
people and understand the requirements of the
cows and the dairy industry.
We encourage and provide training to give the
farmer the choice to get involved with more
technical tasks so to keep downtime and costs
to a minimum.
– Change liners
– Replace ACR cords
– Inspect for leaks
Regular maintenance
Any machine in constant use needs regular
maintenance. Good design makes the day to day
care of Merlin easy for the farmer to carry out.
– Washing down
– Simple visual checks
– Checking chemical
– Changing the milk filter
Dedicated support team
Our Crystal soware is backed by a dedicated
support team that offers online training, support
visits and telephone back-up. Service is carried out
from the clean side of the unit.
Merlin technical specification
2205mm
Fullwood is at the forefront of designing,
manufacturing and supplying milking systems
across the globe.
Page 22 Fullwood and the farmer – What some Fullwood farmers have to say about Merlin
4305mm
Performance Characteristics
– Litres of milk per hour - up to 110 litres per hour
– Power consumption – 0.02-0.03 kwh / litre
– Water consumption – 300 litres per day
(depends on delivery line length)
– 3 services per Year – 1 major & 2 minor services
Dimensions
– Height: 2205mm
– Length: 4305mm
– Width: 1880mm
Weight
– 1500kg
Alloftheabovearesubjecttovariationdependingon
site characteristics and number of milkings per day.
Fullwood and the farmer – Servicing Scheme / Technical Specifications Page 23
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Beer human and animal welfare
Fullwood has vast experience of machine milking –
we were there at its inception. This ensures that
the best knowledge available is utilised in making
life as stress-free as possible for man and animal.
Merlin is one element of the total package Fullwood
can supply for your farm. Identification, management
soware, cooling systems, segregation and feeding
equipment are all available to get the best from
your cows and to improve your work-life balance.