Wagholm Farms: Pioneers in Tie Stall to Robotics

Wagholm Farms in New Hamburg, Ontario, was among the first to show how a tie stall barn can successfully make the leap to automation. Six generations of Wagners have milked cows on the farm, and in 2022, they proudly celebrated 20 years of robotic milking.

Darcy and Vanda Wagner, along with their son Carson, were early adopters of Lely technology in North America. In 2002, when their 160-year-old bank barn needed an upgrade, they chose to retrofit it with a Lely Astronaut A2 automatic milking system instead of building a new parlour.

“We went to an open house and I can still feel the hair come up on the back of my neck when I first saw that robot,” Darcy said. “It didn’t require a holding area and it could fit in our barn. It just felt right from the beginning.”

The switch allowed Wagholm Farms to modernise without rebuilding, a decision that paid off not just financially but operationally. Startup began in January 2002, and though transitioning from a tie stall barn to a facility with free cow traffic and robotic milking had its challenges, the Wagners stuck with it and the long-term benefits were clear. Darcy even credits the system with keeping him in dairy farming longer.

“If it wouldn’t have been for the robot, I would’ve been out of dairy farming quite a while ago. My back and neck issues disappeared after a year or two into robotic milking.”

In 2013, the farm upgraded to a Lely Astronaut A4 automatic milking system, noting improved cow comfort and increased milk production thanks to the I-flow design. They installed that robot in a separate area from the original robotic milker so they could keep milking with the Lely Astronaut A2 throughout installation.

“It was a flawless transition,” Carson said. “The cows were more comfortable with the design of the Lely A4. They walk straight in, can see the herd, and training heifers is much easier.”

The Wagners also enjoy the data that comes with the Lely Astronaut systems.

“The health report provides better insight into somatic cell count (SCC), reproduction and rumination. We can catch issues early, often before we’d even notice them ourselves,” Carson said.

Today, the herd is averaging up to 88 lbs (40 L) per cow per day, with strong components and herd longevity.

The Wagner family’s early leap paved the way for many in their community.

“It’s interesting to see how many people that were watching me very closely 20 years ago now have robots themselves,” Darcy added. “And it’s the next generation that’s pushing it.”

Freedom from the Clock: Milking on Cow Time

In a tie stall barn, the milking schedule drives the entire day. Every hour is planned around it. But with robotics, milking happens on the cow’s time, not yours. Cows choose when to be milked, leading to more frequent milking (typically 2.5–3 times/day), higher production, reduced stress and improved udder health.

Farmers like the Wagners consistently say the biggest surprise isn’t just the performance boost, it’s how much more time they have to manage, not just milk.

Managing the herd instead of doing chores

With tie stall barns, much of the labor on dairy farms is hands-on, including attaching units, cleaning stalls and moving animals. With Lely automated milking systems, those repetitive tasks are automated.

Instead of spending hours in the parlor, the robot handles milking around the clock, freeing up time for bigger-picture decisions. With Lely Horizon farm management system, farmers can monitor heat cycles, detect early signs of mastitis, lameness or reduced rumination, and receive alerts before issues become visible.

At Wagholm Farms, this means fewer surprises and faster treatment.

“The robot lets us know if there’s something wrong, even if the cow looks OK,” Carson said. “We can treat sooner and more effectively.”

As the farm evolves to robots, so do the skills needed to run it. Workers focus less on hands-on milking and more on managing cow flow, interpreting data, and keeping the herd comfortable and productive. The Wagners experienced this shift firsthand, moving from a daily manual routine to data-driven herd management in a free-stall, robot-supported environment.

Here are a few other considerations when moving from a tie stall to a robotic barn:

• Feeding routines are often changed to keep cow flow steady and encourage visits to the robot. Some farms choose perimeter feeding to make it easier for cows to access feed when they need it.
• Bedding practices also change. Instead of working stall by stall, farmers focus on group maintenance. Clean, dry stalls become even more important when cows choose their own time to lie down and milk.
• Hoof and udder care also takes on a bigger role. Regular hoof trimming helps keep cows moving comfortably, and udder and tail trimming support smooth, consistent attachments to robots. Keeping cows healthy and comfortable keeps the entire system running smoothly.

At Wagholm Farms, fine-tuning these routines was a key step in creating a barn where cows are relaxed and productive. Two decades after making the switch, their farm proves that robotic milking isn’t just a short-term solution, it’s a long-term strategy for growth and resilience.

For farmers considering a move from a tie stall barn to automated milking, Harry Linde, general manager of Grand River Robotics in Ontario recommends starting with a local Lely Center, the farm’s nutritionist and the farmer’s other trusted advisers.

“Lely Farm Management Support (FMS) specialists bring extensive experience guiding customers through this transition, making them a valuable resource for planning each step,” Linde said.

Take a look at five common milking robot configurations to consider when designing a new barn layout.

Contact your local Lely Center to discuss any questions you have!