Seven Considerations for Moving from Tie Stall to Robotic Barns

Transitioning a dairy from a tie stall barn to robotic milking isn’t just about adopting new technology, it’s about changing the flow of the barn. This requires detailed planning and careful consideration around barn design, cow traffic and management.

Several years ago in Quebec, Riolait Farms, operated by fourth-generation farmer Jacob Rioux and his father, made the leap from a traditional tie stall barn to a fully automated milking system with a Lely Astronaut A4 automatic milking system.

Riolat Farms Transitions from Tie-Stall to Robots

“In 2015, we installed our first Lely robot, and it completely changed how we manage the barn,” said Rioux, who noted that his father wanted to reduce their dependence on labour, have flexible hours and improve production by adding a robot.

Since installing their first robot, the Riolaits have been very pleased with both its performance and production. With their herd at about 67 cows, one robot was operating at full capacity. With Jacob returning to the farm and increasing production, they chose to add a second robot, a Certified Pre-Owned (CPO) Lely A4.

“It’s fully reconditioned, works like new, and it allowed us to expand while staying within budget,” Jacob said.

Their success reflects what many dairy producers are now discovering — that transitioning from tie stall barns to robotics is not just about new technology, it’s about redesigning both the barn and the workflow for the future of dairy farming.

Barn Considerations for Robotic Milking Systems

In a robotic milking barn, the layout and design should support natural cow movement, reduce stress, and ensure free-cow traffic to and from the robots. Thoughtful planning contributes to herd health, comfort and overall management.

Consider these key points:

1. Cow Flow and Traffic Patterns

2. Robot Placement

Strategic placement of robots in the barn is important. Position robots along routes cows naturally travel — near feed or water lanes — to encourage voluntary and frequent milkings. Ensure that the robot room itself is easily accessible and kept clean. Avoid placing entrances through manure-filled alleys.

Flexible pen configurations can make a significant difference in barn efficiency. Adjustable pens or movable partitions allow producers to manage herd groups, adapt to herd size changes and accommodate future expansions without major reconstruction. Cows should remain in the same social groups throughout lactation whenever possible, as this stability supports comfort and productivity.

Plan how cows will enter groups from the calving area and how they’ll move to the dry cow pen after lactation. Well-designed gates, alleys and cross alleys help streamline these movements, saving time and reducing stress for both cows and handlers.

4. Feed, Water and Manure Management

Feed and water access should align with overall cow flow. Placing ample water troughs along routes to and from the robots encourages cows to drink freely without disrupting others. Consider perimeter feeding to maintain smooth cow flow and to keep them away from high-traffic robot areas.

Manure and stall management must also be carefully planned. Keeping alleys and beds clean and dry aids in udder health and improves milk quality while reducing labour demands. Whether using scraping systems, slatted floors or other manure management methods, cleanliness contributes significantly to a healthy, productive herd.

5. Cow Handling and Care

Ensure cows can easily move from the robot to a separation pen when treatment is needed. If overnight stays are required, plan cow flow between the separation area and the robot to avoid stress and confusion.

Healthy hooves contribute directly to cow comfort and productivity. Foot baths are typically best placed away from the robots, in a crosswalk opposite the milking area, to reduce disturbance during use. However, placement should ultimately fit your specific barn layout and traffic design.

Proper and adequate ventilation is important for herd health and production. Adequate airflow removes humidity and body heat, maintaining a comfortable environment for cows year-round.

Contact your local Lely Center to discuss questions you have about your dairy or click to see more barn layouts.