WPS Farm Show -- March 2023

DRIVING DIRECTIONS

1901 Fish Hatchery Road

Madison, Wisconsin 53713

Toll-Free: 1-888-AGRI-VIEW

Madison Fax: 608-250-4155 agriview@madison.com, www agriview com

Admission: Free

Parking: $5

Free motorized scooters and manual wheelchairs for attendees needing mobility assistance, no reservations needed

Show hours:

Tuesday, March 28 – 9 a.m. to 4 p.m.

Wednesday, March 29 – 9 a.m. to 4 p.m.

Thursday, March 30 – 9 a.m. to 3 p.m.

Location:

Experimental Aircraft Association grounds 1001 Waukau Ave

Oshkosh, Wisconsin

Directions from north of Oshkosh:

U S Highway 41 south to Wisconsin Highway 44/

Ripon Road East – exit 116

Turn left onto Highway 44/Ripon Road East to Knapp Street

Turn right onto Knapp Street

Bear right onto Poberezny Road

Turn left onto Waukau Avenue

Directions from south of Oshkosh:

U S Highway 41 north to Wisconsin Highway 44/ Ripon Road East – exit 116

Turn right onto Highway 44/Ripon Road

East to Knapp Street

Turn right onto Knapp Street

Bear right onto Poberezny Road

Turn left onto Waukau Avenue

Alternate directions from south of Oshkosh: U S Highway 41 north to Wisconsin Highway 26/ County Road N east – exit 113

Turn right onto Highway 26

Turn first left onto Poberezny Road

Turn right onto Waukau Avenue

For more information on visiting Oshkosh, visit www visitoshkosh.com or call the Oshkosh Convention and Visitors Bureau at 920-303-9200 or toll-free at 877-303-9200 Visit wpsfarmshow com for more information on the farm show

FILE PHOTO

Farmers stroll the grounds of the 2018 Wisconsin Public Service Farm Show in Oshkosh, Wisconsin. For many it’s a family outing before they take to the fields for a hectic planting season.

FILE PHOTO

Carole and Clifford Gagas volunteer in a 2018 Wisconsin WPS Farm Show food tent, serving French fries to hungry visitors.

Grow crops in sun-power footprint

DAVE ROEPKE Iowa State University

A new Iowa State University research project will combine traditional and hightech uses of the sun’s power by studying how to grow crops amid an array of solar panels.

Funded by a $1.8 million four-year grant from the U.S. Department of Energy, most of the research will be conducted a few miles south of Ames, Iowa, where Alliant Energy plans to begin construction in April on a 1.35-megawatt solar farm – a partnership with Iowa State announced in fall 2021. A multidisciplinary team of Iowa State University researchers will raise bees and plant vegetables, fruits and pollinator habitat within the 10-acre Alliant Energy Solar Farm at Iowa State University, studying the emerging concept of agrivoltaics. Agrivoltaics means using solar-power sites for agricultural purposes to make moreefficient use of the land and create value for the communities where solar panels are located. The hope is that integrating direct local advantages with solar energy will increase support for such projects.

“As renewable energy grows, it’s important to find opportunities for these projects to benefit people, beyond just providing renewable electricity,” said Anne Kimber, director of the Iowa State University-Electric Power Research Center and a co-principal investigator for the Department of Energy grant. “There’s good work to be done on this front, and we hope this research and demonstration will help identify the potential for communities to benefit from agrivoltaics.”

Construction on the solar farm is expected to be complete this fall. Horticulture research at the site will begin in full in

Iowa State University researchers plan to study mixing solar-energy production and agriculture in a project at a solar farm Alliant Energy will build this year on university land. The research team is led by, from left, associate professor of horticulture Ajay Nair; professor in plant pathology, entomology and microbiology Matt O’Neal; and Electric Power Research Center director Anne Kimber.

spring 2024.

Farming on a solar farm raises numerous questions that need to be explored, researchers say. For one, there’s little data on what plants may still thrive when growing between the solar panels despite receiving partial shade, said Ajay Nair, associate

professor of horticulture and the lead principal investigator. While fruit and vegetable crops typically need full sun, some shade might be a benefit as climate change leads to hotter summers. Identifying crops that grow in the modified microclimate without compromising yield and quality is critical.

There are also practical considerations, Nair said. Equipment used in food-crop operations needs to fit between rows of panels. There are site-management questions to iron out.

“Growing these types of crops under and around a solar farm on a scalable basis is

UNIVERSITY OF MINNESOTA

different than just growing them,” he said. “We want to demonstrate that’s possible.”

Above all, agrivoltaics won’t be possible unless it appeals to growers. Economists will calculate revenue streams from the crops grown at the solar farm to determine if operations can be profitable, and researchers are planning outreach efforts to farmers and nonprofits.

“I think we all feel like there are going to be a lot of eyes on this,” Kimber said. “The people part will be just as important as the scientific research.”

Incorporating research was part of the plan from the start when Alliant Energy and Iowa State University discussed a partnership to build a solar farm owned and operated by Alliant Energy, on land it leases from the university. Nair said Alliant Energy has been enthusiastic about designing the facility to fit researcher needs, including panels of two varying heights – some with a fixed tilt and others with the flexibility to adjust the angle – to allow for more experimentation.

“They’ve been a tremendous partner and collaborator from the very beginning stages of the project and instrumental throughout the planning – generous with their expertise in design and awareness of funding

opportunities,” he said.

Alliant Energy also plans to build the panels with the capability to collect more granular information about energy production than at a standard solar facility. By comparing plot-by-plot energy production with temperature and moisture data collected from Iowa State University sensors under the panels, researchers can see whether crops create microclimate changes that impact the panels.

“Agrivoltaics is so brand-new that there are a ton of questions to be answered,” said Ray Klein, director of the office of college partnerships for the university’s College of Agriculture and Life Sciences. “This grant, and the unique features of the Alliant Energy solar farm, will allow investigation of many of those questions.”

Researchers said the collaboration with Alliant Energy was a big factor in being selected for the Department of Energy grant, which included more than $8 million

in funding spread across six projects.

“This is a great public-private partnership, working with industry on applied science,” Nair said.

Alliant Energy’s strategic-partnerships team thought beyond the singular transaction of a customer-hosted solar project. The team considered how the project could support the agricultural economy, said Nick Peterson, strategic-partnerships manager for Alliant Energy.

“Our efforts to collaborate with Iowa State University and move forward with the research and demonstration components of this project reaffirm our commitment to the agriculture industry,” Peterson said. “Our alignment is an example of how renewable energy and the ag industry can work together.”

Research funding also unlocks the solar farm’s potential for teaching and outreach.

Matt O’Neal, a professor in plant pathology, entomology and microbiology, will

manage the honey beekeeping, along with Iowa State University-Extension specialist Randall Cass. They’ll also measure the response from wild, native bees. O’Neal said he’s looking forward to using the farm as an opportunity for students to explore beekeeping, horticulture and conservation.

“There will be a lot of teaching happening out there,” he said.

In addition to farmers and utility companies, Nair sees the project as a potential draw for the general public – as a way for anyone in the community to see renewable power in action. Kimber envisions 4-H groups and school field trips coming for tours, possibly inspiring future electrical engineers, entomologists and plant scientists.

And this project is likely just the beginning, O’Neal said.

“This is a target-rich environment for research,” he said. “I don’t think this will be the last grant to support this site.”

2023 WPS Farm Show

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FILE PHOTO

A fiberglass cow is an attention-grabber for the Wisconsin Public Service’s exhibit at the 2018 WPS Farm Show.

Dairies can save energy in

ANDY PRESSMAN

National Center for Appropriate Technology

Increasing energy costs and environmental concerns are causing dairy farmers to alter their management practices. Dairy farmers are analyzing their energy inputs and investing in cost-effective energy conservation and energy-efficiency measures. This publication provides an overview of how dairy farms can implement efficiency improvements and energysaving technologies that can reduce energy consumption and energy-related costs.

Dairy farms face challenges and opportunities fueled by rapidly increasing energy costs and concerns about environmental impacts.

Dairy farms use more energy than almost any other agricultural operation. Energy is used in the milking process, and for cooling and storing milk, as well as for heating water, lighting and ventilation. Determining the best energy efficiency and energy-management opportunities for dairy farms will help reduce energy costs, enhance

environmental quality, and increase productivity and profitability.

Energy efficiency is often an inexpensive, quick and simple way to save money. This publication focuses on dairy-equipment upgrades, new technologies and

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management practices for reducing energy consumption

Opportunities for cost savings and improved processes include the implementation of

•variable-speed drives for milk vacuum pumps and milk-transfer systems,

•plate precoolers,

•heat-recovery systems,

•energy-efficient light fixtures and

•efficient ventilation systems.

Information regarding energy audits, financial incentives and further resources is included. The opportunities presented in this publication were developed for cow dairies but may be applicable to goat and sheep dairies as well.

CONSIDER MILKING PROCESS

The milking process consists of harvesting milk from the dairy cow and transporting the milk to a bulk tank for storage. This process can take place one or two or more times per day; most dairies schedule their lactations for a continuous milk supply throughout the year.Onaverage,milkingutilizes18percentof the electrical energy use on a dairy farm.

VACUUM PUMPS HAVE LARGE ENERGY REQUIREMENTS

The vacuum pump operates during the

milk harvest and equipment washing; it can consume 20 percent to 25 percent of all electrical energy use on a dairy farm. The vacuum pump creates negative air pressure that draws milk from the cow and assists in the milk flow from the milk receiver to either the bulk tank or the receiver bowl.

The airflow also sends water and cleaning agents through the milking system during the washing process.

There are four main types of vacuum pumps – sliding vane rotary pumps, waterring pumps, rotary lobe or blower pumps, and turbine pumps. Each of these operates

and uses energy differently. Vacuum pumps become less efficient as the vacuum level increases. Therefore operating the vacuum pump at reduced vacuum levels conserves energy.

Sizing the vacuum pump to meet the needs of the milking and washing system can reduce capital costs for equipment, reduce energy operating costs during the life cycle of the pump and ensure the pump is performing properly The size of the vacuum pump is dependent on all of the components in the system that admit air during operation. Pumps are generally sized by accounting for the amount of air admitted into the milking system during the milk harvest – plus a 50 percent reserve to account for accidental air admittance, and the wear and tear of parts. Outdated industry standards would recommend oversized vacuum pumps in part because of an incorrect belief that additional vacuum capacity is necessary for washing. An oversized vacuum pump may overheat as the pump ends its cycle The current industry performance standard, ASAE Standard S518.2 Feb03, Milking Machine Installations, provides current sizing guidelines for dairy vacuum pumps.

Please SEE Energy, Page 13

NATIONAL CENTER FOR APPROPRIATE TECHNOLOGY

A vacuum pump operates during milking and equipment washing and is often the primary electrical energy user.

Corey Kuchta Supervisor 920-433-2913

MEET YOUR TEAM

AGRICULTURE SERVICES

Fred Daniels Energy Efficiency Adviser 414-750-4093

Chuck Imig

Antigo, Eagle River, Marinette, Menominee, Merrill (east of Hwy. 51), Minocqua, Oconto County, Rhinelander, Tomahawk, Wabeno, Wausaukee 920-617-5228

Minocqua Wabeno

Rhinelander Merrill Antigo

Marinette/ Menominee

Wausaukee Kewaun ee

Rob Juneau Brown County and Door County 920-617-5108

Wausau Oshkosh

Sturge on Bay

Stevens Point Green Bay

Chilton

WPS Ag Consultants

Alan Gregory Kewaunee and Two Rivers 920-657-1834

Two Rivers

Sheboygan

Alex Geiser

Chilton, Reedsville, Kiel, Sheboygan 920-849-7904

Jason Zilisch

Merrill (west of Hwy. 51), Oshkosh, Stevens Point, Waupaca, Wausau 715-345-7561

FILE PHOTO

The U.S. flag and the Wisconsin Public Service flag wave in the breeze above the grounds of the 2018 Wisconsin Public Service Farm Show in Oshkosh, Wisconsin. Farmers turn out in force at the show to view the latest technology and equipment in agriculture.

FILE PHOTO

Wyatt Hesselink, left, and his twin brother, Garret Hesselink, both then 6, inspect an Apache sprayer in the Vanderloop Equipment exhibit at the 2018 WPS Farm Show in Oshkosh, Wisconsin. The twins are the sons of Ben Hesselink, a dairy farmer from Oostburg, Wisconsin.

Know What’s Below

Being safe during digging projects is as easy as“811.”

Before picking up that shovel, call to have buried gas piping located – for free.Because skipping this important step can mean explosive consequences.

LOCATE BURIED PIPING

Call 811 and ask to have the pipeline and all other facilities located. Allow three full working days for energy companies to respond and locate the facilities in the area.

WPS uses permanent markers to indicate the presence of gas lines in the area Those markers usually are not set over the pipeline but are used to indicate gas pipelines in the area.

You can rely on the paint and/or flag markings put on the ground by WPS to give the approximate location of facilities. Remember, any digging done near marked facilities must be done by hand. Never assume that your equipment won’t hit the facilities because you think they’re located at a greater depth.

KNOW ABOUT NATURAL GAS

atural gas is a colorless,odorless and nontoxic gas that is used as an energy source.To make it easier to detect gas leaks, a harmless but pungent-smelling chemical is added to give natural gas a distinct odor

When mixed with air, natural gas can be explosive. Although some natural gas-air mixtures will not burn, the only safe practice is to assume that leaking natural gas is always explosive and dangerous.

Signs of a natural gas leak include •unexplained areas of dead vegetation where the surrounding area is green, •distinct natural gas odor similar to rotten eggs,and

•blowing sound or bubbling in a wet or flooded area.

If you smell natural gas, don’t look for the source of the gas leak; get out immediately!

Call the WPS 24-hour natural gas emergency line from your mobile phone or a neighbor’s home,at 800-450-7280.

VARIABLE-SPEED DRIVES ENERGY-EFFICIENT

A variable-speed drive, also referred to as an adjustable-speed drive or variablefrequency drive, is an energy-efficient technology used for controlling the vacuum level on sliding-vane rotary pumps and rotary-lobe pumps. Traditional vacuum systems run at maximum speed only; they rely on a vacuum regulator to vent excess air that is not being used during milking or washing operations. A variablespeed drive adjusts the speed of the pump motor to meet the vacuum demand so that equal amounts of air are being removed by the vacuum pump and entering the milking system. By eliminating the amount of air that would be admitted through a regulator, the motor uses less horsepower during most of the milking process. A variable-speed drive on a vacuum pump eliminates the need for a conventional regulator because less energy is delivered to the motor and its operating speeds are reduced. Energy operating costs of a vacuum system with a variable-speed drive

can be reduced by as much as 60 percent. In addition, reducing the vacuum pump’s RPMs can extend its life because there will be less wear and maintenance costs.

VACUUM-PUMP MAINTENANCE IMPORTANT

Following the manufacturer’s maintenance schedule, along with routine maintenance on all vacuum-pump systems, can save energy. Checking the temperature of the vacuum pump near the end of each milking is a good way to detect problems with the pump or electrical load. High motor temperatures may indicate the need for a vacuum adjustment, removal of exhaust restrictions, repair of rotary-vane oiling systems or cleaning lobe-blower pumps. Changes in the speed of the vacuum pump can be caused by air leaks in the milking system, degraded drain seals, loose pump belts, malfunctioning pulsators or a malfunctioning variable-speed-drive vacuum sensor. A 5-cubic-foot-per-minute air leak in the vacuum system can amount to more than $100 in wasted electrical costs as of 2008. Problems associated with vacuum pumps can be avoided by regularly checking vacuum levels and the operation of the variable-speed drive.

MILK-COOLING SYSTEMS USE MOST ENERGY

Cooling milk accounts for most of the electrical-energy consumption on a dairy farm. Milk is harvested from a cow at about 95 to 99 degrees Fahrenheit. To maintain excellent milk quality, including low bacteria counts, the raw milk temperature needs to be reduced quickly to about 38 degrees. Refrigeration systems consist of a bulk tank, a motor-driven compressor unit, an evaporator and a condenser unit. The system operates by pumping a refrigeration coolant in a cycle that gives off heat as it condenses. Heat exchangers cooled by well water, variablespeed drives on the milk pump, refrigeration heat-recovery units and scroll compressors are all energy-conservation technologies that can reduce the energy consumed in the cooling system.

There are two types of milk cooling systems used on dairy farms. A direct-expansion cooling system cools the milk directly in the bulk tank by using evaporator plates that expand in the lower portion of the tank. Indirect or instant cooling systems rely on heat exchangers to precool the milk before it enters the bulk tank. A precooling heat exchanger can reduce milk temperatures as much as 40 degrees, resulting in refrigeration-energy

reductions of about 60 percent.

HEAT EXCHANGERS PRECOOL MILK

Heat exchangers used for precooling raw milk transfer the heat from the milk to an intermediate cooling fluid – such as well water or a water-glycol solution – by having the milk and coolant flow in concurrent or counterflow configurations. In a concurrent flow configuration, the milk and coolant flow in the same direction. The fluids flow in opposite directions in a counterflow pattern. Counterflow systems allow for cooler milk temperatures. The amount of cooling that takes place depends on the flow of the milk in relation to the flow of the coolant in addition to the heat-transfer area, the number of times the milk passes through the coolant and the temperature of the coolant.

Well-water heat exchangers have been implemented in precooling systems for more than 20 years and can reduce cooling costs by 0.2 to 0.3 kilowatt hours per hundredweight of milk. There are two types of heat exchangers used for precooling – shell-and-tube heat exchangers and plate heat exchangers. Shelland-tube heat exchangers consist of a single small tube or multiple small tubes inside of

Please SEE Energy, Page 28

2023 WPS Farm Show Exhibitors, listed alphabetically

BioMass

Bioret

Bitmasked

Bonnie’s Honey Bees C5719

Bremer Bank D6568

Brooks Tractor Inc O5175

Brunner Seed Inc A3614

Bug Tussel/AT&T C5725

Bush Hog B4594

Byron Seeds, LLC A3586

Calf Star LLC D6648

Calumet Dryer Services LLC A3599

Casper’s Truck Equipment C5641

Central Ag Supply Inc D6577

Chris Shafer Agency, LLC C5522

Cleary Building Corporation C5632

Cole Oil Co. C5588

Commercial Laundry Sales Inc C5575

Compeer Financial A3511

Condon Oil - Ripon & Coloma C5644

Contree Sprayer & Equipment Co LLC A3509

Country Clipper C5716

Country Visions Cooperative B4644

Countryside Environmental Solutions/ Countryside Dairy Solutions C5728

CP Feeds LLC B4649

Cressoni/Cressco USA Inc D6565

Crop IMS, LLC A3581

CropSource LLC/Pivot Bio C5586

Crown Royal Outdoor Stoves A3510

Crystal Creek Natural LLC NT0116

CTW Corporation C5595

Culpitt Roofing Inc B4613

Custom Safety Groovers C5507

D & D Equipment Co. Inc A3519 A3543

Dairy Business Association/ Edge Dairy Farmer Cooperative A3580

Dairy Farmers of Wisconsin B4576

Dairy Lane Systems LTD D6582

Dairy Star C5606

Dairyland Seed Co Inc D6542

Dairyland Structures C5515

Dan Hagenow Video Creation, LLC B4582

DBC Ag Products/LIRA GOLD B4563

2023 WPS Farm Show Exhibitors, listed alphabetically

Foxland Incorporated C5503 C5546 C5549

Frenchville Trailer Sales LLC NT0132 O3300

Fritsch Equipment Corp B4641 O4145

G.A. Miller Company LLC NT0134

GAT Supply Inc D6522

GEA D6552

Gingerich Structures NT0117

Glaus Industries, LLC O5165

GLC Minerals C5590

Golden Harvest C5637

Graetz Mfg., Inc C5608

Grandpa’s Shelters & Sheds, LLC O3245

GreenStone Farm Credit Services B4561

Gruett’s Inc C5733 O5105

GVD Feed Covers LLC D6550

H & S Manufacturing Co Inc O3060 A3527

H&S Fencing and Supply B4515 O4045

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2023 WPS Farm Show

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2023 WPS Farm Show Exhibitors, listed alphabetically

Uddermatic Inc C5639

United States Department of Agriculture NT0110

Unverferth Manufacturing Company Inc C5529

US Screen D6524

UW Madison Farm & Industry Short Course B4619

UW-Oshkosh College of Nursing

2023 WPS Farm Show Exhibitors, listed alphabetically

Wisconsin

Wisconsin

Wisconsin

Wisconsin

Wisconsin

Wolf

WPS

WPS

WPS

WPS

YES

Zeeland

B4625

Zerk Zapper/Horizon Products C5580

Ziegler Ag Equipment C5695 C5737

Zimmerman Manufacturing O5120

Harvest air from underground

JASON MALONEY

For Agri-View

BRILLION, Wis. – Everybody knows a farm needs to make money to stay in business. Crops and livestock must pay. And if there was a way to make more money by cutting costs, or raising more crops on the same land, most people would do it. But sometimes simple answers are difficult to find because they’re so common to us we don’t see them.

In the 1950s my dad dug a big hole down to bedrock on the edge of our yard. Our farm lacked a root cellar so dad decided to make one. He erected walls of concrete blocks and made a ceiling of reinforced concrete. Dirt from the excavation was piled neatly over the roof. That root cellar kept all our vegetables fresh for months each year by using the almost-constant temperature of the ground a few feet below the surface. It was cool in summer and warmer than freezing all winter. It turns out, my dad was harvesting energy that’s available on practically all farms. Instead of buying electricity or gas for heating or cooling a storage room, the ground was doing it for free.

Could that constant temperature of the ground on a farm be used to heat or cool larger buildings like barns? If energy under farm fields could be harvested it would be like having two crops on the same field at the same time – one on the surface and one underneath.

Colleen Vanderloop, owner of the AVA Group near Brillion, has since 2017 been harvesting energy from the ground on her farm. AVA Group specializes in raising calves and assisting other calf farms.

“The system has been working well,” she

said. “The main reason I installed it was to heat our barns. We exchange the air in the barns several times each hour; we heat the barns to 62 degrees. The temperature of the

ground is between 48 and 55 degrees.”

Heating 48- to 55-degree air to 62 degrees

Colleen, Brooke and Bettina Vanderloop sit on hay bales in a calf barn at AVA Group of Brillion, Wisconsin. The structure is heated and cooled, in part, with energy stored by nature in the ground under a nearby field.

Jason Maloney and Red

CONTRIBUTED

A row of air-intake pipes are visible above the snow along a field at AVA Group near Brillion, Wisconsin. Air drawn through the pipes is changed to a year-round uniform temperature by the ground under the field. That helps heat calf barns in the winter and cool them in the summer.

Maloney

From 25

requires much less energy than heating outside winter air to 62 degrees. But what about during summer?

“My daughter and I were in the barn one hot summer day,” she said. “It dawned on me that we didn’t need to exchange the air in the barns as often in the summer anymore because we were drawing air cooled by the ground, not hot air from outside. We don’t have to run as many fans in summer.”

Fred Daniels is part of the We Energies and Wisconsin Public Service energy-services team.

“The system simply draws air through the ground,” he said. “It’s a negative-pressure system. There’s a series of 21 corrugated plastic pipes about 300 feet long buried in the ground. The pipes come to a manifold that comes into the barn. Fans on the exhaust side of the barn suck air through the pipes 365 days a year. The WPS energy-efficiency services team just calculated that at $1.80 a gallon, this system is saving about $7,500 per year in propane cost.”

Vanderloop has developed expertise with her ground-energy system by experimenting through the years. She shares her expertise through her consulting business.

“I know how people can put in these systems correctly,” she said. “There are times of the year, parts of spring and fall, when the air outdoors is closer to the 62-degree air we need in the barns. Those times of the year we don’t need to draw from the ground system. Systems need to be right-sized for the buildings they help heat and cool.

“These systems can reduce heat stress for cattle in summer. Farmers have fields. Many

Air is drawn through a row of intake pipes along a farm field at the AVA Group. LEFT: A large manifold pipe brings air collected from smaller intake pipes into a barn after the air temperature has been changed to a uniform temperature by the ground under a farm field. That air heats barns in winter and cools them in summer.

Air is drawn into the intake pipes in the foreground, then under the farm field and into the calf barn. The ground alters the temperature of the air to match the temperature of the ground. That air heats the barn in the winter and cools it in the summer. Crops of hay are made on the field while crops of temperate air are harvested from beneath the same field at AVA Group near Brillion, Wisconsin.

have drain tile under fields that are easily located by modern (global positioning) systems. If farmers install ground-energy systems under their fields they will know where they’re located.

“We make hay on the field where our system is buried. Farmers can use fields with ground-energy systems under them just like they use fields with drain tile under them. Fields can be multipurpose.

“Farmers can get more production from cows in summer if we can keep them cool. Reproduction is better. Milk production is better.”

It turns out my dad was on to something with that root cellar. Using energy under farm fields that’s free for the taking can heat

farm buildings in winter and cool them in summer. Farmers can harvest two crops from a field at once. Livestock production can increase while gas and electric bills decrease. Visit www.avagroupinc.us and www.wisconsinpublicservice.com for more information. Contact Fred Daniels at fred.daniels@ wecenergygroup.com or 414-750-4093.

Jason Maloney is an “elderly” farm boy from Marinette County, Wisconsin. He’s a retired educator, a retired soldier and a lifelong Wisconsin resident. He lives on the shore of Lake Superior with his wife, Cindy Dillenschneider, and Red, a sturdy loyal Australian Shepherd.

Fred Daniels

A screen and covering keeps debris from entering intake pipes in the underground energy system at AVA Group near Brillion, Wisconsin.

Energy

From 13

a larger tube. The milk flows through the smaller tube(s) while the well water flows throughthelargertube Plateheatexchangers are comprised of a series of metal plates that are located side by side Milk and well water run in opposite flow channels; the well water absorbs the heat from the milk on the opposite side of each plate. Plate heat exchangers are relatively small in size and, unlike shelland-tube heat exchangers, additional plates can be added to increase capacity.

Heat exchangers are designed so that the milk and coolant make single or multiple passes between the plates or tubes In a single-pass heat exchanger, a circuit is arranged so the two fluids are in contact as they go throughseparatesetsofplatesortubesbefore exiting the heat exchanger. Multiple-pass heat exchangers route the milk and coolant flow through two or more circuits, putting the milk channels in contact with the coolant channels for longer periods of time. A heat exchanger can be designed so the milk travels through multiple circuits and the coolant flows through a single pass or circuit. Farms that milk for long periods of time can use heat exchangers that are designed for two

coolants.Theuseoftwodifferentcoolingfluids, such as first precooling with well water and then with chilled water or a glycol-water solution,can cool the milk as it is harvested.

PRECOOLER SAVES ENERGY

Installing a properly sized precooler can reduce refrigeration energy consumption by about 60 percent A properly sized well-water heat exchanger can reduce milk temperatures to within 5 to 10 degrees of the groundwater temperature. Higher efficiency for precooling can be achieved with a 1-1 ratio of coolant to milk flow,and by using the largest water lines possible in order to maximize the coolant flow. Other factors that determine the energy and economic savings of a precooler include herd size, number and size of compressors, type of coolant used and the age of the bulk tank. An added benefit of using water for precooling is that it can afterward be used for livestock drinking water. Cows depend on drinking water to produce milk and prefer warm water to cold. The warmwatercanalsobeusedtoperformother tasks such as washing and heating.

VARIABLE-SPEED PUMPS REDUCE ENERGY NEEDS

As previously stated, a vacuum is required to harvest milk. The milk, however, cannot

NATIONAL CENTER FOR APPROPRIATE TECHNOLOGY

A well-water precooler, far right, cuts compressor use by using groundwater to pre-cool the milk.

transfer from a pipeline that is under a vacuum to a bulk tank that is at normal atmospheric pressure. To compensate for the difference in pressure, milk can flow into a receiver bowl that triggers a milk-transfer pumptopushthemilkfromthereceiverbowl either through a heat exchanger or directly into the bulk tank. Another option that eliminates the receiver bowl and milk-transfer pump requires putting the bulk tank under a vacuum by placing rubber seals on the bulktank covers.

A variable-speed milk-transfer pump can furtherreduceenergyusebyslowingtheflow rate of milk through the heat exchanger. A lower and more continuous milk flow rate through the heat exchanger increases the coolant-to-milk ratio and results in greater milk cooling. Milk can be cooled by an additional15to20degreesbyinstallingavariablespeed milk transfer pump.

REFRIGERATION RECOVERY UNITS CAPTURE HEAT

Refrigeration heat-recovery units capture the waste refrigeration heat from the condenser to preheat water before it is transferred to a water heater. A refrigeration heatrecovery unit can recover 20 percent to 60 percent of the energy that’s required to cool milk for storage. Depending on the number

of cows being milked, the refrigeration heatrecovery unit’s storage tank should be sized to provide enough hot water for one milking. Thisincludeshotwaterforwashingthemilking system and for washing the bulk tank. The payback for purchasing a refrigeration heat-recovery unit depends on the savings from heating water and will vary greatly from farm to farm

HEAT-RECOVERY UNITS INEXPENSIVE

There are two types of refrigeration heatrecovery units – desuperheating and fully condensing units. A desuperheating unit operates only when the refrigeration system operates and produces water temperatures of about 95 to 115 degrees These units can be inexpensive to add but only part of the available heat can be transferred to the water. Almost all the available refrigeration heat is recovered as hot water from a fully condensing unit, with temperatures reaching 120 to 140 degrees. This type of refrigeration heat-recovery unit meets the requirements of the cooling system by using a valve to control the flow of cold water through the heat exchanger. Once the storage tank is full, excess warm water can continue to be used

Please SEE Energy, Page 31

PEOPLE’S ENERGY COOPERATIVE Hoffman Farms is a 300-plus-head dairy with 800 acres just west of Chatfield, Minnesota. Hoffman Farms saved energy and money on dairy technology through People’s Energy Cooperative energy-savings rebates. By placing a variable-frequency drive on a 15-horsepower milk pump, the dairy is saving 25,590 kilowatt hours during a 4,000-hour annual run time and $450 in energy rebates. Switching their dairy-parlor lights to light-emitting diodes resulted in excellent savings as well. Changing 26 two-lamp fixtures from T-8 fluorescent bulbs to linear light-emitting-diode bulbs saved 3,333 kilowatt hours and $312 in energy rebates, and another 42 T-8 fluorescent bulbs in different fixtures to linear light-emitting diodes saved 1,116 kilowatt hours and resulted in $168 in energy rebates

S.D. Ellenbecker! Specializing in all type of concrete construction, including a variety of dairy industry and agricultural structures

Cost effective... All-metal construction requires fewer posts and columns. A standard all-metal barn would contain four columns instead of six found in most wood barns.

Innovative construction methods... Ellenbecker is one of the first to introduce an all-metal frame method of agricultural construction to the area.

Durable, safer materials... Structures are far less susceptible to fire since no wood is used in the construction process. Buildings are more resistant to natural elements than wooden counterparts.

The

•

•

•

•

2023 WPS Farm Show Exhibitors, listed by category

ASSOCIATIONS/ORGANIZATIONS

BLOOD PRESSURE/CHOLESTEROL

T H Agri-Chemicals Inc A3506

COMBINES

S.I. Distributing D6538

DRILLING

Service Motor Company D6658,D6627,O6000

Swiderski Equipment Inc C5533,C5559

Vanderloop Equipment Inc D6501,D6526,O6032

COMPUTERS/COMPUTER SOFTWARE

Bitmasked Automation B4591

Bug Tussel Wireless/AT&T C5725

Dan Hagenow Video Creation, LLC B4582

Feed Supervisor- Hoof Supervisor-Truck Supervisor A3568

CONCRETE PRODUCTS/MANURE STORAGE

A & M Concrete and Construction NT0135 Extrutech Plastic Inc C5613

JP Tank Inc B4622

KBM Construction Inc C5624

BIOGAS/ANAEROBIC

CALF

CONCRETE

Uddermatic Inc C5639

CAMERA MONITORING

DL Agriculture Electric Inc. D6594

CARTS/WAGONS

Big Iron Equipment B4550

Demco B4538

CHEMICALS/PESTICIDES

BioMass Sales & Consulting B4638 Cole Oil Co. C5588

From 29

and not wasted. A fully condensing refrigeration-heat-recovery unit replaces the need for a regular condenser in the refrigeration system and is best integrated as part of a new or replacement refrigeration system If almost all the energy captured by the refrigeration heat-recovery unit is used for preheating water,then a precooler is not needed to remove heat from the milk and may, in fact,increase overall energy costs.

COMPRESSORS VARY

The function of a compressor is to compress the cold low-pressure refrigerant gas fromtheevaporatortoahigh-pressurehightemperature state for condensing. The three types of refrigeration compressors used for milk cooling on dairy farms are the reciprocating,scroll and discus

•The reciprocating compressor is the most common and can be either open type, hermetic or accessible hermetic.

•The scroll and discus compressors are newer and more efficient than reciprocating compressors. Research has shown that replacing a failed reciprocating compressor with a new scroll compressor can reduce milk cooling costs by 20 percent because of a reduction in the electrical demand.

HOT WATER ESSENTIAL

Hotwaterisessentialforproducingexcellent-quality milk on dairy farms and is primarily used for cleaning milking systems. The amount of hot water required varies from farm to farm; it depends on the size of themilkingherd,andthetypeandsizeofthe milking system. On average a minimum of 4 gallons of water at 170 degrees are required for each milking unit. Hot water is generally produced by water heaters that use either fuel oil, natural or propane gas, solar energy or electricity. For some dairy farms, heating watercanaccountforabout25percentofthe total energy used on the farm.

There are several ways to reduce the amount of energy used for heating water. Whether using a direct or indirect water heater, overall efficiency is determined by the combustion efficiency of the fuel source and the amount of heat loss from the storage tank – known as standby loss. A direct water heater combines the water-storage tank and the heating element. The storage tank in an indirect water heater contains a heat exchanger that is connected to a separate boiler unit. Insulating the storage tank and connecting pipes can reduce standby losses for both types of water heaters. The

Please SEE Energy, Page 40

• Maintenance-Free

2023 WPS Farm Show Exhibitors, listed by category

Kozlovsky Dairy Equipment Inc

MEDA /Chem-Star

ProActive Solutions USA, LLC

Stanley Schmitz Inc

DRONES/UNMANNED AERIAL VEHICLES

Agri Spray Drones

Dan Hagenow Video Creation, LLC

Eagle Eye Ag Drones LLC

EDUCATION AgrAbility of Wisconsin

WhichBarnisBestForYourHerd?

•PoleSheds

•FreeStalls

•PavilionShelters

•MachineryStorage

•RidingArena

Birdsjustlovethisbarn.Thewebsinthese trussesareeasynestareasforbirds.Theyalso restrictairflowwhichleadstopoorventilation andmoisturebuildupinthebuilding.

•Spansupto72ft.

Thearchedrafterscreateamoreopenbarn allowingbetterventilation.Alsosincethere arenoopenwebsinthetrusses,thereare noplacesforbirdstonest.

•AdditionalCeiling

ELECTRIC MOTORS/EQUIPMENT/SUPPLIES North Central Irrigation Inc B4511

ELECTRIC UTILITY

Alliant Energy - Wisconsin Power & Light C5596

WE Energies A3535

Wisconsin Public Service A3533

ENERGY CONSERVATION/EFFICIENCY

Alliant Energy - Wisconsin Power & Light C5596

Focus on Energy A3503

MEBULBS NT0119

Midwest Meter A3590

Straight Arrow Energy C5607

WaterFurnace International C5618

WE Energies A3535 Wisconsin Public Service A3533

2023 WPS Farm Show Exhibitors, listed by category

2023 WPS Farm Show Exhibitors, listed by category

Kuhn North America Inc A3619

Oxbo International NT0166,O3285

Riesterer & Schnell Inc A3615

RMH Mixers C5662

Schraufnagel Imp Inc D6625

Swiderski Equipment Inc C5533,C5559

Vanderloop Equipment Inc D6501,D6526,O6032

Walco USA Inc C5671

HITCHES

Bergman Manufacturing Inc B4566

HOOF HEALTH CHEMICALS/EQUIPMENT

AgroChem B4575 FARM Inc C5599 Feed Supervisor- Hoof Supervisor-Truck Supervisor

HYDRAULIC EQUIPMENT/PARTS Applied Industrial Technologies

Premier Insurance Solutions D6585

& S Manufacturing Co Inc O3060,A3527

INDUSTRIAL

INOCULANTS Advanced Preservative Systems

Feeds LLC

DBC Ag Products/LIRA GOLD B4563

Deaton Nutrition Inc C5657

La Crosse Seed A3609

Microbial Products of Wisconsin D6611

Partners in Production, LLC B4592

Peak Forage Solutions C5664

Strong Microbials, Inc C5594

INSULATION/SPRAY FOAM

Pro Foamers, Inc D6593

INSURANCE

5G Benefits & GOEBEL Insurance C5610

Bremer Bank D6568

Chris Shafer Agency, LLC C5522

Compeer Financial A3511

Kyle Lange Agency, LLC A3572

Nicolet National Bank A3603

2023 WPS Farm Show Exhibitors, listed by category

2023 WPS Farm Show Exhibitors, listed by category

PLASTIC

2023 WPS Farm Show Exhibitors, listed by category

B4566

Big Iron Equipment B4550

Eden Equipment C5731

Farmers’ Implement A3635

Gruett’s Inc C5733,O5105

Landoll Company, LLC C5551,O5000

Puck Enterprises D6545

Real Harrows LLC C5627

SMA, Inc C5600

Swiderski Equipment Inc C5533,C5559

Unverferth Manufacturing Company Inc C5529

Walco USA Inc C5671

Zimmerman Manufacturing O5120

TMR MIXERS/EQUIPMENT

Farmers’ Implement A3635

Foxland Incorporated C5503,C5546,C5549

Kuhn North America Inc A3619

TRUCKS/CAPS/LINERS/EQUIPMENT

SILAGE

TILLAGE

Zerk Zapper/Horizon Products C5580

TRACTORS/TIRES/RELATED SERVICES

Bobcat Plus C5711

D & D Equipment Co Inc A3519,A3543

Diesel Specialists of Green Bay, Inc B4568

Fairchild Equipment C5525

Farmers’ Implement A3635

Forklift Tire Inc C5619

Joe’s Auto Body Tractor LLC B4512

Knowles Produce & Trading Co O6060,D6530

Riesterer & Schnell Inc A3615

Service Motor Company D6658,D6627,O6000

VISIT AGRI-VIEW IN BOOTH D6573

sides and top of an electric water heater, and the sides of gas and oil water heaters, can be insulated

WATER TEMPERATURES

IMPORTANT

Proper water temperatures are essential for cleaning milking equipment. Using warm or cold water when possible can help reduce energy costs. A warm-water pre-rinse, about 95 to 110 degrees, does not cause the milk to stick to the equipment, which is a problem with cold water. Additionally, a warmwater rinse does not cause mineral and protein deposits in the pipeline, as is often the case when using hot water. The wash cycle requires water temperatures between 120 and 170 degrees. Dairy farms require the use of commercial water heaters because residential electric water heaters are thermostatically controlled not to go warmer than 140 degrees because of federal safety regulations. The thermostat range for commercial water heaters is 100 to 180 degrees.

A cold acid rinse will control mineral and bacterial buildup in the milk lines and will help conserve hot water. There are many

types of dairy acid sanitizers and each one may have different rinse instructions.Most of these sanitizers are not listed on the National

CONTRIBUTED

– but some may be permitted for use on organic dairies Check with an organic certifier to see if they have any restrictions for use of dairy acid sanitizers

Using a control device for electric water heaterscanreduceelectricityuseduringperiods of expected increases in demand to more than the average supply level, also known as peak demand Time clocks provide a simple and cost-effective way to control water heaters Shifting electrical loads to off-peak or reduced-demand hours and off-peak utility rates not only ensures farmers of having hot water at a reasonable cost, but also benefits the utility provider by allowing direct control of the energy demand on their system. Many utility companies offer incentive rates or rebates to encourage farmers to participate in electric-water-heater control programs. Not all utility companies offer off-peak utility rates, so it is best to check with local service providers to see if off-peak rates are available.

LIGHTING IMPROVES PRODUCTIVITY, SAFETY

List

for the National

Organic Program

of Allowed and Prohibited Substances for use in certified organic production and processing

Appropriate lighting can improve productivity and safety on a dairy farm On average, lighting represents 17 percent of total dairy farm electrical energy use. Optimal lighting conditions may increase milk productivity and conserve energy consumption. Factors

that contribute to increased milk production include the type of light, the amount of light provided per watt, the temperature of the work area, the height of the ceilings and the length of the lighting period.

Lighting requirements on a dairy farm can be divided into three categories. The first category is visually intensive task lighting, which requires the highest lighting levels. Areas that benefit from this type of lighting include milking parlors; equipment washing, equipment maintenance and repair areas; offices; maternity and veterinary-treatment areas; and utility rooms. The second category includes lighting for holding areas, feeding areas, animal sorting and observation, and general cleanup. These areas and tasks require high to moderate lighting levels. Finally, low to moderate lighting levels are adequate for general lighting for livestock resting areas, passageway lighting, general room lighting, and indoor and outdoor security lighting.

There are three types of lighting systems used on dairy farms – incandescent lamps, fluorescent lamps and high-intensity discharge lamps.

Incandescent lamps – Incandescent lamps are common on many dairy farms, although today they are considered to be an inefficient light source. Their light output is only 10 percent, with the remaining 90

percent of energy given off as heat.

Fluorescent lights – Fluorescent lights are made of a frame, ballast, light socket and the lamp(s). Ballasts provide the needed voltage, current and waveform for starting and operating fluorescent and high-intensity discharge lamps. The lamps are available in many different lengths and diameters, shapes, color-temperature ratings and minimum operating-temperature ranges. Fluorescent lamps range in length from 6 to 96 inches long. The diameter of the lamp is expressed in eighths of an inch. Lamps come in the following diameters – T-5, T-6, T-8, T-9, T-10, T-12 and T-17. A T-12 lamp is 12/8 inch, or 1.5 inches, in diameter, while a T-8 is 8/8 inch, or 1 inch in diameter.

Fluorescent lamps are linear or straight, circular or U-shaped. The color-temperature index, or CCT, refers to the color appearance of the light emitted by a lamp. It is indicated in degrees Kelvin or K. Cooler temperature values produce a red or orange color, and refer to a warm emitted light. Warmer temperature values produce a blue, or cool, light source. The CCT values for fluorescent lamps range from 3,000 to 5,000 degrees K, while the average CCT value of an incandescent lamp is about 2,800 degrees K. Minimum operating temperatures for fluorescent lamps are between -20 and 50 degrees Fahrenheit,

depending on whether the ballast is electromagnetic or the more-energy-efficient electric type.

The most common type of fluorescent lamp is the T-12. However, smaller-diameter lamps provide more light for a watt of power. Compared to a T-12 lamp and ballast, the T-8 fluorescent lamp provides about 15 percent more light, or lumens, and the ballasts are 40 percent more efficient. The most energyefficient fluorescent lamp is the T-5, but that lamp tends to produce too much heat in an enclosed fixture. Enclosing fixtures in agriculture lighting systems protects the housing from corrosion, and protects the lamp from dust, humidity and manure gases, all of which can shorten the life of a lamp.

A compact fluorescent lamp or CFL uses about 75 percent less energy, measured in watts, for the same amount of light as an incandescent bulb. CFLs are directly interchangeable with incandescent lamps, so changing a 60-watt incandescent lamp to a 20-watt CFL cuts energy use by one third. CFLs also last six to 10 times longer than incandescent light sources. CFLs can be used outdoors, but should be covered to protect the lamps from all weather conditions. Cold temperatures, both indoors and outdoors, may reduce light levels. In order to reach full output at cooler temperatures, CFLs require a

warm-up period.

High intensity discharge or HID lamps are a very bright and efficient light source. HID lamps often require a warm-up period and generate light by heating a gas mixture in the lamp. HID lamps must be mounted high in order to spread the light and to avoid a glare. Some HID fixtures can be equipped with a diffuser that distributes the light horizontally. The four common types of HID lights are mercury vapor, metal halide, highpressure sodium and low-pressure sodium.

1. Mercury-vapor lamps emit a favorable blue-white color that mimics daylight. However, mercury vapor lamps are the least efficient of the HID lamps, emitting only 32 lumens for a watt. In addition, their disposal poses an environmental risk due to the mercury gas.

2. Metal-halide HID lamps provide the best color of all the HID lamps and emit about 60 lumens a watt, making them twice as efficient as a mercury-vapor lamp. A newer pulse-start lamp technology is available for metal-halide lamps. The pulse-start system can extend lamp life by half as compared to the standard metal-halide lamp, provide about 8 percent more lumens per watt, and allow for faster warmups and restarts. Please SEE Energy, Page 52

2023 WPS Farm Show - Hangar A

Consider twofold energy savings

University of Minnesota

The agricultural industry consumes an immense amount of fossil fuels in the production of food, feed, fiber and energy. From the electricity that cools milk, to the fuel that is burned in combines and tractors in grain fields, to the trucks that bring goods to market, and to the nitrogen fertilizer that nourishes plants; the agricultural industry is captive to large and constant supplies of a wide range of fossil energy. Agriculture’s dependence and thirst for fossil fuels carry significant economic, environmental and social risks for the nation and world. Agrivoltaics is one way producers might be able to become less dependent on fossil fuels, reduce production costs, increase land efficiency, improve forages and crops for use by dairy cattle, and increase milk production and health in dairy cows. Using a ground-mounted photovoltaic system in a dairy setting

Brad Heins, assistant professor and University of Minnesota-Extension organic-dairy specialist, and Kirsten Sharpe, graduate student, in 2019 discuss a 30-kilowatt solar-powered system in the pasture of their rotationalgrazing system at the University of Minnesota-West Central Research and Outreach Center in Morris, Minnesota. The system provides shade for their milking herd and energy for the milking parlor.

UNIVERSITY OF MINNESOTA

Hydra-Ramtwo-stagespreadersfeaturehydraulic pushcylindersandmovingplatformsthatdeliver lesscompaction,lowermaintenance, andamoreevenspreadpattern.

QUICKDETACHVERTICALBEATERS•CONTOUREDPUSHPLATE•2-YEARWARRANTY

could provide shade to dairy cows during extreme heat events and provide farmers with an alternative means of income.

Through past investments and institutional experience in renewable energy and dairy-production research, the University of Minnesota-West Central Research and Outreach Center has a globally unique opportunity to lead a new green revolution – a revolution that greens energy currently consumed within the agricultural industry. The Morris dairy operation milks 275 cows twice daily and is representative of a midsize Minnesota dairy farm. The cows are split almost evenly between a conventional and a certified-organic grazing herd

There is no research that has investigated the use of a ground-mounted solar system to provide shade for dairy cows and to determine the effects on dairy cows. Therefore our team wanted to investigate the effects of shade from solar-photovoltaic panels on the production, health and behavior of pastured dairy cows.

During the summer of 2018, a 30-kilowatt ground-mounted solar system was installed in a pasture at the center. The panels were mounted at 35 degrees south and 8 to 10 feet from the ground so cows

Please SEE Energy, Page 47

Hourly body-temperature results show that no-shade cows had greater internal body temperatures than shade cows from 1 p.m. to midnight. Between milking times – 10 a.m. to 8 p.m. – the shade cows had cooler internal body temperatures than no-shade cows All cows had similar body temperatures during the nighttime hours.

2023 WPS Farm Show – Hangar B

couldn’t reach the panels. The solar panels were Heliene panels – Heliene Photovoltaic Modules of Marie, Ontario, and Minneapolis – using Solar Edge – Solar Edge of Fremont, California – inverters and optimizers; they were installed by Zenergy of Sebeka, Minnesota. The cost increase for mounting the panels above the cows was minimal. The total cost was about $90,000.

The pastured-dairy-cow study was conducted from June 2019 through September 2019 Twenty-four crossbred cows were assigned to one of two treatments – shade from solar photovoltaic or no shade The no-shade cows didn’t have access to any shade on pasture.

All cows had a CowManager ear-tag sensor to record ruminating and eating as well as not active and active behaviors for all cows. Also a SmaXtec bolus was placed in the reticulum of the cow and recorded internal body temperature, as well as activity and drinking bouts of cows. Daytime ambient high temperatures during the study ranged from 81 to 93 degrees Fahrenheit.

•The shade and no-shade cows were similar for behavioral measurements and fly numbers on cows.

•The shade cows had less overall high activity than did no-shade cows, because they were standing underneath the solar panels during the hot hours of the day.

•Daily drinking bouts were similar for cows

•Respiration rates for shade and noshade cows were similar during the morning hours. But during the afternoon, shade cows had slower respiration rates at 66 breaths per minute than no-shade cows at 78 breaths per minute.

•Surprisingly, production for milk, fat and protein were not different for cows whether they had shade or no shade Quite possibly no difference was observed for production because cows were only under the shade for 28 days of the 175 days the cows grazed during the summer. Longterm effects of milk production may have been observed had cows been under the shade for the entire summer

•Hourly body-temperature results show that no-shade cows had greater internal body temperatures than shade cows from 1 p.m. to midnight. Between milking times – 10 a.m. to 8 p.m. – the shade cows had cooler internal body temperatures than no-shade cows. All cows had similar body

Please SEE Energy, Page 48

couplers, Screw-Type

Volvo TEMA couplers, and Multi-Coupling units. With name brands like Faster, Stucchi, Parker, and Holmbury, we can provide custom hydraulic options to best fit your needs!

Energy

From 47

temperatures during the nighttime hours. Based on the results of the study, cows may have sacrificed grazing time to stand in the protection of the shade.

Future research with our solar panel will investigate

• cow reproductive performance;

• long-term effects on milk, fat and protein production;

• long-term effects on body weight and body condition; and

• long-term effects on animal health and well-being.

Our study indicates that agrivoltaics may provide an acceptable method of heat abatement to pastured dairy cows, as well as generating electrical energy for farmers – thus reducing the carbon footprint of the dairy operation. In the future we will be exploring tracking systems for solar in livestock farms, using solar panels as windbreaks for cattle, and evaluating crops and forages that will grow best under solar systems. Economic impacts of the agrivoltaic system and land productivity from solar farms will drive the adoption of solar photovoltaic systems on farms.

VISIT AGRI-VIEW IN BOOTH

D6573

1-800-662-8356

COMMERCIALGRADELAUNDRY EQUIPMENTFORCOWTOWELS

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www.lorriganconstruction.com•800-235-3252

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LUBRICANTS

Ourobjectivehasalwaysbeenquality, performanceandvalue.Weofferlubricants forallyourfarmneeds.

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Poweryourfarmessentialswitha clean-burning,easy-to-use,reliablefuel!

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FILE PHOTO

Where’s the beef? It’s at the Wisconsin Cattlemen’s Association food booth at the 2018 WPS Farm Show in Oshkosh, Wisconsin. Manning the grill are Glenn Erickson, left, a beef producer from Neenah, Wisconsin; and Brady Calaway, a beef producer from Chilton, Wisconsin.

FILE PHOTO

Brooke Wiedenfeld, then 4, of Lake Mills, Wisconsin, gives it her all during the children’s pedal-tractor pull at the 2017 WPS Farm Show. The little girl ignores crowd noise to concentrate on her technique. Her parents are farmers Luke and Beth Wiedenfeld.

“ComevisitusatC5642”

2023 WPS Farm Show - Hangar C

(920)309-0255

RYANDURRANT NorthcentralWI (715)467-1770

BILLGAUSMAN NorthwestWI (715)684-9755

TREVORKNUTSON NorthwestWI (715)307-2779

STEVEVANDENPLAS EasternWI (920)366-6322

BRIANGRADE CentralWI (920)948-7223

CRAIGROBINSON WesternWI (715)491-0707

LUKEBIRD SoutheastWI (262)206-4729 MONTYBURNS SouthwestWI (563)329-0301 CHADBUTTS SouthernWI (608)290-3191

Databasedon2022FIRST(Farmers’IndependentResearchofSeedTechnologies)and2022UniversityofWisconsincorngraintrials. NoproductrecommendationbyFIRSTisimplied.

Pulse-start metal-halide lamps use a differenttypeofballastandarenotinterchangeable with standard metal-halide lamps

3. High- and low-pressure sodium lamps are slightly more efficient than metalhalide lamps. High-pressure sodium lamps emit about 95 lumens a watt and give off an orange light. A 100-watt high-pressure sodium lamp can provide 2.5 times more light than a 100-watt mercury-vapor lamp while using significantly less energy.High-pressure sodium lamps are often used for mixed outdoor and indoor lighting applications. Lowpressure sodium lamps are the most efficient HID light source, but produce a poor color of light. Low-pressure sodium lamps are often used for outdoor security lighting.

•Incandescent – 5-20 lumens per watt

white – 2800 correlated color temperature – for general lighting

•Fluorescent, T-8 and T-12 – 30-110 lumens per watt – bluish to white – 27006500correlatedcolortemperature–formilking parlor, milk room, holding area, office, equipment washing,maternity,veterinary

•Compact Fluorescent – 45-72 watts per lumen – white – 2700-6500 correlated color

temperature – for general lighting

•Mercury Vapor – 24-60 watts per lumen – bluish – 3200-7000 correlated color temperature – used for outdoor lighting

•Metal Halide – 41-110 watts per lumen

bluish

3700 correlated color temperature – used for milking parlor, holding area, milk room, equipment washing, maternity, veterinary

•High-pressure Sodium – 50-140 watts per lumen – yellow-orange – 2100 correlated color temperature – used for milking parlor, holding area,feeding area,outdoors

•Low-pressure Sodium – 60-150 watts per lumen – yellow –… – used outdoors

•Efficiency is defined as the ratio of light produced – lumens – to energy consumed – watts

Replacing inefficient light sources with an appropriate and higher-efficiency light can result in better task lighting with energy savingsthatcontinuethroughthelifeofthelamp. Energy-conservation opportunities involve changing incandescent lamps to compact fluorescents, upgrading to smaller-diameter and more-efficient fluorescent lamps, and upgrading to HID lighting Because lighting fixtures distribute light in different patterns, the barn layout and use should be considered in any lighting decision.

Energy savings can be achieved by using

simple and inexpensive technologies that go beyond lamp replacement Some technologies incorporate programmable logic controllers and other computer-based control systems; they include timers, dusk-to-dawn photo controllers, half-night controllers and motion detectors. New and more efficient technologies are continually being developed. Several factors can shorten the life of a lamp.

•level of manure gases

•humidity

•dust

•frequent switching on and off

LONG-DAY LIGHTING INCREASES PRODUCTION

Long-day lighting is a new development for dairy farms that involves increasing milk production by extending the day length with artificial light. According to researchers, dairy cows are day-length sensitive and can be stimulated to increase milk production by providing 16 to 18 hours of uninterrupted lightingfollowedbysixtoeighthoursofdarkness. By implementing an efficient longday lighting system, milk production can be increased by 5 percent to 16 percent.’

PROPER VENTILATION CRITICAL

Proper ventilation is needed in dairy barns

throughout the year to help maintain animal health and productivity, the barn’s structural integrity,milk quality and a comfortable work environment for the laborers The air inside a barn becomes warm and humid because cows continuously produce heat and moisture An efficient ventilation system brings fresh air that is cooler and drier into the barn; it mixes and circulates it, and exhausts and dilutes moisture, dust, manure gases and odors, and airborne contaminates.

Cows that are exposed to fresh air are less likely to develop heat stress, respiratory ailments, mastitis, reproductive problems and other diseases that could decrease milk production. Many dairy producers are realizing the inherent benefits of a grass-based product ion system. Grass-based dairies utilize an ecological approach to health care by relying on natural immunity that comes with pasture access. According to experts, heat stress in dairy cows begins when surrounding temperatures exceed 65 degrees and the relative humidity is 40 percent or more. Maintaining a healthy atmosphere by controlling mold, spores, dust and other irritants also helps reduce the chances of milk contamination and reduces health risks to the farmers. Good ventilation also reduces building deterioration due to excess moisture, which can cause rot,mildew and electrical problems.

There are two types of ventilation – natural and mechanical Natural ventilation uses the least amount of energy and requires the exchange of air, the ability to control ventilation rates, flexibility to provide the cows a comfortable environment throughout the year and good barn construction. Barns that are in the path of prevailing winds and designed with adjustable side and end walls can take advantage of breezes and thermal buoyancy, and minimize unexpected air exchanges.

Mechanically ventilated barns require air inlets and exhaust fans opposite one another. Exhaust fans are powered by an electric motor and contain hoods, protective screens,and louvers or shutters.Each fan targets a certain area to provide uniform control of moisture and gases. Ventilation fans used in livestock buildings are typically axial flow fans, which are designed to let air pass straight through the fan parallel to the fan blade drive shaft.Traditional ventilation systems are designed with air inlets and exhaust fans placed on opposite ends of a building, whereasairinletsandexhaustfansinacrossventilation system are located on opposite sides of a building.

A properly designed and sized ventilation-fan system should provide the required amounts of ventilation needed to maintain a

comfortable environment for the cows and the laborers during each season The blade size and shape, fan speed in terms of revolutions per minute or rpm, motor horsepower and housing design determine how much air a fan can move. This is known as fan capacity and is measured in cubic feet per minute or cfm. The size of ventilation system needed depends on its capacity to remove excess moisture during the milder and colder months of the year while forcing cool air through the building during the summer to reduce animal heat stress.Exhaust fans range in size from 5 inches in diameter to 72 inches. Exhaust-fan motors may be as small as 1/20 horsepower and may exceed more than 50 horsepower.

Static pressure is the difference in pressure between inside and outside of a building, ventilation fan or air inlet It is measured in inches of water or inches of mercury. The static pressure of an efficient exhaust fan should be between 0.05 and .125 inches of water; it’s measured with a manometer.

Circulation fans are mounted inside buildings to help improve air movement and to reduce dead-air spots There are different types of circulation fans, all of which have propeller blades attached directly to a motor

NATIONAL CENTER FOR APPROPRIATE TECHNOLOGY

Circulation fans help improve air movement inside a barn.

2023 WPS Farm Show - Hangar D

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Fans are thermostatically controlled in a freestall barn at Leeds Dairy The facility was constructed by Fox Cities Builders RIGHT: Wind speed should be at least 7 miles per hour anywhere cows congregate such as holding pens.

Energy

From 53

or to a motor-and-belt drive system. Two commontypesofcirculatorfansusedindairy housing systems are box fans and high-volume-low-speedfansorHVLS.Box-typefans

generally operate at moderate to high levels of efficiency, depending on the fan diameter, with the larger diameters being more efficient.

HVLS fans are large-diameter circulation fans with diameters ranging from 8 to 24 feet One 24-foot HVLS fan can move the same amount of air as six 48-inch

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800-444-FARM

SLAC NATIONAL ACCELERATOR LABORATORY

A row of fans are connected to a dairy barn’s power system to help keep cows from overheating.

LYNN GROOMS, AGRI-VIEW

high-speed box fans and can save as much as 3.3 kilowatts in an hour of operation. HVLS fans save energy by replacing existing circulation fans that are not efficient. In addition, HVLS fans tend to be quiet, reduce moisture in buildings, and reduce fly and bird populations in barns.

The Air Movement and Control Association International is an independent testing laboratory that rates fans on their ability to move air. Fans that meet certain AMCA or other reliable testing-performance criteria receive a certified rating seal of approval. This rating can be helpful to select the proper fan for an intended use.

The use of thermostats to control ventilation systems reduces energy consumption by having the fans operate only when needed. Properly located thermostats should accurately reflect the average temperature inside the building. Mounting a thermostat at least 10 feet from a fan and at least 1 foot below the ceiling reduces the thermostat’s exposure to adverse factors –such as sunlight and air intake drafts – that can alter the thermostat’s temperature reading. All control systems should be located so they cannot be bumped by the livestock.

Timer controls and moisture sensors can also be used to control ventilation rates. However, the use of these control devices

may not save energy. Timer controls cycle motors on and off to meet set ventilation rates and may use more energy to start the motors from the off mode. Timer controls also create larger temperature swings. Furthermore, moisture sensors have been reported not to work adequately in barns.

Dairy ventilation systems require routine maintenance to keep fans operating at high performance levels. Poorly maintained fans and obstruction to air inlets and fan outlets can reduce fan efficiency by as much as 40 percent to 50 percent. Cleaning fan parts, lubricating bearings and other moving parts, checking belt tension and alignment, and removing any obstructions will keep fans performing at peak efficiency and reduce energy costs. Long-term efficiency can be improved by repairing or replacing bent, damaged or misaligned fan blades, shutters, guards and other fan parts. An air-velocity meter can be used to detect reductions in the performance of the ventilation system. Control systems should be cleaned regularly and thermostats should be checked yearly for accuracy by comparing their readings against a mercury thermometer.

Several factors affect the efficiency of a livestock-ventilation system.

Please SEE Energy, Page 60

FILE PHOTO

Tunnel ventilation and recycled sand keep cows comfortable inside dairy facilities at Ebert Enterprises, the Algoma, Wisconsin, farm that hosted the 2017 Wisconsin Farm Technology Days.

Analyze on-farm energy efficiency

DANIEL

CIOLKOSZ

Pennsylvania State University

Energy is used to heat, cool, plant, harvest, clean and perform a wide variety of tasks on the farm. But the price of energy can sometimes be a real obstacle to a farm being profitable.

Energy efficiency on the farm is probably more important now than ever Farms that utilize their energy efficiently tend to have a much better prospect for being successful in the current economy.

Farms use energy in a variety of forms electricity, gasoline, diesel fuel,propaneandnaturalgas. Renewable energy resources such as biogas or biomass can also be produced as well as used on the farm. But they must all be used effectively if a farm’s profitability is to be maximized.

The most important step in improving a farm’s energy efficiency is to understand current energy use on the farm That cannot be done by intuition alone. A careful assessment of the farm’s energy use is necessary to know where energy is being used. It’s not uncommon to find unexpected “energy hogs” equipment or processes that use more energy than they should.

Once the existing energy usage is determined, it’s time to consider what sort of changes can be made to reduce energy use and operating costs. Those changes are often referred to as “energy-conservation measures” or ECMs. Some energy-conservation measures can save a great deal of energy with minimal cost or trouble; those arealwaysthemostdesirable.Otherenergyconservation measures may be less worthwhile if they save only a small amount of energy at a relatively inflated cost or hassle to the farmer. Energy-conservation measures can be as simple as changing a temperature setting or as complex as replacing multiple pieces of equipment with more efficient devices

Generating a list of energy-conservation measures for a farm isn’t always an easy process. It often requires experience with farms as well as with energy systems.

The most common way to compare energy-conservation measures is to calculate their “simple payback.” That’s the number of years that it takes for the savings of an energy-conservation measure to cover

the cost of installing the measure. If a new energyefficient fan costs $300 to install, but reduces electricity costs by $100 per year, the payback is three years. Shorter paybacks tend to be better,with four to five years often considered the maximum for many commercial operations.

An energy-conservation measure shouldn’t be considered if it reduces the performance of the farm unless the savings in energy is so great that the reduction

in performance is worth the investment in the long run. Deciding that trade-off is not a simple matter It involves both economic analysis and using one’s best judgment.

Reducing energy use is not the only way to save on an energy bill and make a farm more profitable. There are several related strategies that involve changing the way that energy is used that could also yield savings including demand management and renewable generation.

Demand management is the method of controlling the time in the day when electricity is used,in order to reduce costs.Some farms usually larger ones pay a charge for the maximum rate at which electricity is used. All farms may soon be required to pay

for “real-time pricing” of electricity that varies cost during the course of the day. In either situation it’s possible for farmers to adjust their operating schedules to reduce their electricity charges.

The other major related issue to energy efficiency is the opportunity for farmers to produce renewable energy on the farm That reduces the amount they need to purchase from off the farm. One popular option is the production of biogas from animal manure. Another possibility is to grow energy crops. Visit extension.psu.edu and search for “energy” for more information.

Daniel Ciolkosz is an assistant professor at Pennsylvania State University.

Daniel Ciolkosz

Energy

From 57

•ventilation-system design

•fan-blade type and design

•efficiencyofelectricmotorstopowerfans

•use of fan-control system

•routine maintenance and cleaning

AUDIT FARM ENERGY REGULARLY

A farm-energy audit is a tool to help agricultural producers conserve energy and save money by implementing energy-efficient equipment. The audit collects and analyzes information on farm energy consumption and its associated costs, and then makes recommendations on ways to reduce them Farm-energy audits also explore ways to capture renewable-energy resources that are available on a farm. Dairy operations are often good candidates for farm-energy audits because there are significant opportunities for dairies to save energy and money through conservation and efficiency measures. Farm-energy audits can be conducted by a professional or through do-it-yourself energy-efficiency calculators. There are several federal, state and nonprofit grant and incentive programs for implementing energy efficiency and

renewable-energy systems on dairy farms. Visit www dsireusa org and www rd usda gov/about-rd/agencies/rural-businesscooperative-service for more information.

SUMMARY

There are many opportunities for dairy farms to reduce their electrical-energy consumption Dairy farms can become more energy efficient by upgrading older equipment, installing new technologies, and changing management practices for milk harvesting, milk cooling and storing, ventilation and lighting. An energy audit can be a valuable tool to a dairy farmer who is trying to understand how energy is currently being used on the farm and identify cost-saving opportunities

Visit www.ncat.org for more information.

Andy Pressman is an agricultural specialist with the National Center for Appropriate Technology Visit www ncat org for more information.

Dave Ryan, National Center for Appropriate Technology energy engineer, performs a farm energy audit

Long-day lighting worth considering

University of Wisconsin

When cows are exposed to long days, 16 to 18 hours, research has shown they will give 4 to 5 pounds more milk per day Long days can be created by exposing the cows to artificial or a combination of natural and artificial light.

In a tie-stall barn that can be accomplished by installing a row of light-emitting diode tubes, T-8 or T-5 fluorescent fixtures, over the feed alley In a free-stall barn, light-emitting diode, metal halide or high-pressure sodium lamps are normally used unless the ceiling height is less than 10 feet. Then light-emitting diode or highoutput T-8 fluorescent fixtures would likely be recommended.

Long-day lighting will generally not work for farms milking three times per day because it’s nearly impossible to achieve six to eight hours of darkness due to milking schedules. It might be possible to achieve for a select number of groups but likely not the entire herd.

Most dairy barns are too dark. Improving barn lights and operating them according

to a specific schedule can improve both the profitability and working conditions on a dairy farm That technique is known as long-day lighting or photoperiod control. It has been well researched in the past 20 years.

Benefits are many.

•increased milk production

•improved heifer growth

•more enjoyable

•safer working conditions

INVESTMENT CREATES PROFIT

Studies have shown that exposing cows to supplemental light during the short days of fall and winter can increase milk production by about 5 percent to 16 percent. But cows also eat more, and there’s a cost to install

CONTRIBUTED

Most dairy barns are too dark Improving barn lights and operating them according to a specific schedule can improve both the profitability and working conditions on a dairy farm.

and operate the lights. The increased milk yield pays for the extra feed and the cost of the lights – and still leaves a net profit. Estimated investment costs and pay-back

Please SEE Lighting, Page 62

UNIVERSITY OF WISCONSIN

Gehl Skidloaders and Track Loaders McHale Balers & Wrappers Massey Ferguson Compact Tractors

Hoffman Farms is a 300-plus-head dairy with 800 acres just west of Chatfield, Minnesota. Hoffman Farms saved energy and money on dairy technology through People’s Energy Cooperative energy-savings rebates. By placing a variable-frequency drive on a 15-horsepower milk pump, the dairy is saving 25,590 kilowatt hours during a 4,000-hour annual run time and $450 in energy rebates. Switching their dairy-parlor lights to light-emitting diodes resulted in excellent savings as well. Changing 26 two-lamp fixtures from T-8 fluorescent bulbs to linear light-emitting-diode bulbs saved 3,333 kilowatt hours and $312 in energy rebates, and another 42 T-8 fluorescent bulbs in different fixtures to linear light-emitting diodes saved 1,116 kilowatt hours and resulted in $168 in energy rebates.

Lighting

From 61

periods for lights in a 40-cow tie-stall barn range from $1,672 paid back in 111 days to $2,125 paid back in 332 days

CREATE 16-18 HOURS LIGHT, 6-8 HOURS DARK

Most of the experiments with long-day lighting have provided supplemental light, extending the fall and winter days in September through March or April – creating 16 to 18 hours of light per day. The effects of the technique are well-documented. A producer can expect a substantial production increase by using a consistent program of 16 to 18 hours of light followed by six to eight hours of darkness. Note that consistent night-off and early morning-on timing is necessary to achieve an increase in milk production.

WORKPLACE SAFER, MORE PRODUCTIVE

Trivial accidents such as slips and falls happen during barn chores. They may be disabling and are occasionally fatal. Good lighting helps workers spot obstructions and slippery areas. Better lighting also makes it easier to notice cows in heat, cows with health problems, cows off feed, poor feed quality, etc. In addition most people appreciate a well-lit workplace and consequently may become more productive.

IMPROVE LIGHTING IN STALL BARNS

Cows are stimulated to produce more milk

when they register longer days through their eyes and brain. The average light intensity in the barn needs to be at least 15 foot-candles at cow-eye level. That can be achieved by installing sealed fluorescent-light fixtures over the manger. Avoid using incandescent lamps because they are not energy-efficient and have a short bulb life. In most stall barns natural daylight is insufficient. Therefore the manger lights need to also be on during the day. To ensure consistent light and dark

periods, a timer should be installed.

IMPROVE LIGHTING IN FREE-STALL BARNS

To stimulate milk production, provide an average of 15 or more foot-candles in all areas where cows spend time. Be sure to provide sufficient light also to outside free-stall rows. Certain work areas such as treatment, breeding and feeding require 20 or more foot-candles. Metal-halide and

high-pressure sodium lamps provide good light output and have a long lamp life. Both represent energy-efficient options for freestall barns.

The amount of natural light in non-insulated, naturally ventilated free-stall barns during daytime typically exceeds 20 footcandles. Thus the lights can normally be turned off for most of the day and operated only during early-morning, late-afternoon and evening hours. Install a timer to achieve consistent on-off times. A photo sensor should be installed to save energy during normal days, but automatically keep the lights on during exceptionally dark winter

APPROPRIATE FOR MOST DAIRY OPERATIONS

Long-day lighting is profitable and feasible for stall barns and free-stall barns of all sizes. Farmers should take advantage of the opportunity to improve profitability and working conditions. A simple light meter can tell whether the amount of light in a stall barn is too dim. Measuring light levels after the installation can verify that new lights deliver light levels required to stimulate milk production. Area utility-company representatives and county agents may be able to assist with measuring light levels – or provide a light meter on a loan basis. Otherwise a simple light meter can be purchased for $100 to $150.

This material was developed by the Wisconsin Healthy Farmers, Healthy Profits Project, whose goal is to find and share work-efficiency tips that maintain farmer health and safety, and also increase profits. Visit bse.wisc.edu or call 608-262-7408 for more information.

CONTRIBUTED

Studies show that exposing cows to supplemental light during the short days of fall and winter can increase milk production by about 5 percent to 16 percent.

ONTARIO MINISTRY OF AGRICULTURE, FOOD AND RURAL AFFAIRS

Figure 2. Summary of nine studies reports the effect of long-day photoperiod on milk yield in lactating cows.

PEOPLE’S ENERGY COOPERATIVE

LIGHTING FACT SHEET

WHAT TO DO IF A CFL BREAKS

Compact fluorescent light bulbs (CFLs) use up to 75 percent less energy and can last 10 times longer than traditional incandescent bulbs. Although CFLs contain only a small amount of mercury, it’s best for the environment and for the health and safety of yourself and others to properly clean up after a broken CFL. The U.S. Environmental Protection Agency (EPA) recommends the steps at right to safely dispose of the debris.

FOR LOCAL INFORMATION ON RECYCLING LIGHT BULBS

Check with your local county recycling program to see if there are local restrictions for light bulb disposal. Some municipalities require luorescent bulbs (broken or unbroken) be taken to a local recycling center. If there is no such requirement in your area, you can dispose of the materials with your household trash. Otherwise, dispose of the materials at your local recycling center.

CFLS AND THE ENVIRONMENT

The growing popularity of CFLs has prompted some to question the bulbs’ mercury content and its effect on the environment. Like all luorescent lamps, CFLs contain small amounts of mercury –an average of ive milligrams of mercury per bulb. By comparison, some watch batteries contain 25 mg of mercury, and many thermostats contain up to 3,000 mg.

RECOMMENDED STEPS

1 Have people and pets leave the room.

2 Open nearby windows for 5-10 minutes to disperse any vapor that may escape and shut off the central heat/air conditioning system, if you have one.

3 Carefully sweep up the glass fragments using stiff paper or cardboard (do not use a vacuum or broom), and place them in a lidded jar or sealed plastic bag.

4 Use sticky tape, such as duct tape, to pick up any remaining small pieces and powder. Wipe the area with damp paper towels. Place the towels in the sealed bag.

5 If vacuuming is needed after visible materials are removed, vacuum the area where the bulb was broken. Remove the vacuum bag (or empty and wipe the canister) and put the bag or vacuum debris in a sealed plastic bag.

6 Promptly place all bulb debris and cleanup materials outdoors until the materials can be disposed of properly.

7 Continue to air out the room where the bulb was broken for several hours, leaving the heating and air conditioning system off.

CFLs are perfectly safe to use; they do not emit mercury when they are intact, in use, properly stored, handled, or installed. And because CFLs use less electricity, they are actually responsible for fewer mercury emissions than traditional incandescent bulbs. A power plant will emit more mercury producing the electricity to light an incandescent bulb than to run a CFL for the same length of time.

FOR MORE INFORMATION

To ind out how you can reduce energy costs and improve the comfort, safety, and durability of your home, call Focus on Energy at 800.762.7077 or visit focusonenergy.com/residential.

Environmental Protection Agency epa.gov/bulbrecycling

Wisconsin DNR dnr.wi.gov/topic/Recycling/bulbs.html

SAVING ENERGY AND MONEY FOR WISCONSIN