Managing TMR Variation

Improving Feeding Consistency and Efficiency with TMR Audits DAIReXNET Webinar Dr. Tom Oelberg, Ph.D. toelberg@diamondv.com

Outline
What Is A TMR Audit
Factors that Contribute to TMR Variation
Managing Ingredient variation and shrink
Labor Efficiencies
Summary of Diamond V TMR Audit Data

4 Rations
Ration formulated
Ration that is mixed
Ration the cow consumes
Ration that is pushed out

What Is A TMR Audit?
Value-added service provided by Diamond V
An on-farm evaluation of the
Feed Storage and Preparation,
Mixing and Delivery of the TMR
Ingredient Variation and Shrink
Utilization of Labor and Resources
Reduce Variation and Improve Efficiency

TMR Audit Tools
Feeding Software TMR Batch Summaries
“ Help Us Focus on Issues”
Feed Supervisor
TMR Tracker
EZ-Feed
Feed Watch
Others
Digital camera with video capabilities
Penn State Shaker box
Stop watch
Quart-sized Zip-loc bags
One-cup sized scoop
Grain sieves
Thermometer
Infrared camera
Data collection sheets

10 samples per load
Penn State Shaker Box Used on each Sample
Samples of Weighbacks to compare to TMR
Calculate average and coefficient of variation (CV) for each load
The CV is a measure of consistency…lower the better
Top 25% loads of TMR have 3% CV or less
Penn State Shaker Box To Measure TMR Particle Size Variation

Well Mixed TMRs Obtained By Different Methods Twin-twin screw vertical wagon Mixed with payloader turning pile 5 times Horizontal auger reel mixer

“ Feed Particles Mix When Falling Together At the Same Time” “ Any ingredient or process that interferes with this will affect TMR consistency”

TMR Consistency Results via Penn State Shaker Box Test Goal: < 5% CV for Middle and Bottom Screens

An Inconsistent Lactation Ration

Contributing Factors to TMR Variation Dirty Dozen
Capacity
Mixing Times
Equipment Wear
Hay Quality & Processing
Unlevel TMR Loading
Pre Batch Variation
Grain Particle Size Variation
Ingredient Inclusion Amt
Ingredient Mix Order
Loading Liquids
Deliver Times
Silage Face Management

Horizontal Reel Mixer Overfilled? Video One

Horizontal Reel Properly Mixing Video Two

Proper Mixing Action For A Vertical Wagon Courtesy: Supreme International website

Supreme International’s Feedlot Auger

Supreme International’s Forage Processing Auger

Over-Filling Causes TMR Variation

Case 1. Over-Filled Kuhn-Knight Reel-Auger Model 3700

Penn State Shaker Box Results Lactation Rations Load 1 Over-filled Load –Lactation Ration TMR felt drier

Penn State Shaker Box Results Lactation Rations Load 2 Over-filled Load –Lactation Ration TMR Felt Drier

Penn State Shaker Box Results Lactation Rations Load 4 Normal Filled Load – Lactation Ration

TMR Consistency Results via Penn State Shaker Box Test Oelberg. 2009. Reducing load size on Kuhn-Knight Reel-Auger Model 3700 reduced variation (CV %)

Case 1. TMR Consistency of Over-filled vs. Normal-filled Reel-Auger Mixer Oelberg. 2009. Courtesy to Hubbard Feeds, Mankato, MN for providing lab analysis Kuhn-Knight Reel-Auger Model 3700

Close-up Mixing…Mineral Mix Hanging Up on Screws

Load Size Too Small Mineral Not Completely Delivered To the Close-up Dry Cows

Proper Mixing Time Reduces Variation Harner et.al. 1995 K-State MF-2503 5% CV after 5 to 6 minutes

Count Down To Mix Last Added Ingredient

Sharp vs Dull Blade

Effect of Dull Knives on Large Round Bale Processing Oelberg. 2008. Dry Cow Ration

Effect of New Knives on Large Round Bale Processing Dry Cow Ration Replacement Heifer Ration

Wear and Stress Fractures on Edge Deflectors (Kicker Plates) Video Three

Worn Augers Video Four

Mixing Large Rounds of Alfalfa…Tough Middle Core

Haylage Clumps

Inconsistent Nutrient Consumption of a Poorly Mixed Fresh Cow TMR Video Five

Improper TMR Loading Causes Under-Processed Hay Not Loading On Center Loading On Center… Line Up on The Red Triangle

Hay Not Loaded Between Augers Causing It To Not Get Completely Processed

Hay Not Getting Completely Processed

Under-Processing Hay “Big Factor”

Clumps of Under-Processed Hay In TMRs

Penn State Shaker Box Results Load 1, Mix 1 min Restrictors Out Load 3, Mix 3 min Restrictors Out Load 4, Mix 3 min Restrictors In

Influence of Adjusting Hay Restrictor Settings and Load Mixing Time On TMR Particle Size Consistency Goal: 5% CV or less for Middle/Bottom Screens

Results of Processing Hay Ahead of Time
Previous slides showed dairymen that extra mixing time did not reduce forage particle size
Convinced him to process all hay needed for the day ahead of time and dump in a pile
Loaded processed hay from pile faster and more accurately resulting in a more consistent TMR
Results:
Milk fat test increased from 3.6% to 3.9% within a week
Milk protein test increased from 3.00% to 3.15% within a couple of weeks

Make Sure Wagon Is Level: Triolet 3-Screw Parked In Loading Ramp

Triolet Triple-screw Wagon Over-loaded At Back of Wagon Loading un-level wagon with back of wagon lower than the front causes feed buildup in back of wagon

Influence of Loading An Un-level Triple-Screw Wagon On TMR Particle Size Distribution Along The Bunk Load 1 Load 2 Front Back Back Front Bottom and top screens of shaker box go up and middle screen goes down as TMR moves from front to back of the wagon

Influence of Loading An Un-level Triple-Screw Wagon On TMR Particle Size Distribution Along The Bunk

Un-level Triple-Screw Wagon During Loading Causes Variation In TMR Goal: < 5% CV for Middle and Bottom Screens

Proper Ingredient Mix Order

Improper Loading and Under Mixing of Liquid Supplements In TMRs
Case 1 – Wagon not level and under mixing liquid supplement
Case 2 – Loading at improper position on wagon
Case 3 – Loading at improper position on wagon and influence on nutrient distribution in the TMR

Case 1. Mixer Not Level, Liquid Added Without Spray Bar and Mixed For Only 1 minute

Case 1.Influence of Not Properly Mixing Liquid Supplement On TMR Particle Size Along The Bunk Mixer truck was not level as the front of the truck was sloped down hill. TMR was mixed for only 1 minute or less after liquid was loaded. The TMR was extremely wet at the front of the load when it was dropped and dry at the end. Small feed particles on bottom pan stuck to larger particles in top and middle screens at the front of the load. The effect was consistent across all 4 loads.

Case 1. Influence of Not Properly Mixing Liquid Supplement On TMR Particle Size Variation Mixer truck was not level as the front of the truck was sloped down hill. TMR was mixed for only 1 minute or less after liquid was loaded. The TMR was extremely wet at the front of the load when it was dropped and dry at the end. Small feed particles on bottom pan stuck to larger particles in top and middle screens at the front of the load. The effect was consistent across all 4 loads. Penn State Shaker Box Screens TMR Loads Top Middle Bottom Load Pens Situation Avg., % CV,% Avg., % CV,% Avg., % CV,% 1 Lactation Front of Load Wet 8.0 28.6 66.1 10.96 25.8 35.45 2 Lactation Front of Load Wet 6.7 27.3 65.9 13.59 27.4 37.95 3 Lactation Front of Load Wet 5.3 38.9 64.9 9.45 29.8 21.01 4 Lactation Front of Load Wet 7.6 25.9 62.5 14.34 29.8 23.46

Case 2. Liquid Supplement Loaded Improperly In a Twin-Screw Vertical Mixer Wagon and TMR Particle Size Oelberg. 2009. Solid Lines = Improperly loaded Dashed Lines = Properly loaded Beginning Ending

Case 3. Adding Liquid At End and At Center of the Wagon

Case 3. Improper Loading of Liquid Caused Variation In Moisture and Particle Size of TMR Along the Bunk Note: As moisture level increases from front to back of wagon, amount of TMR on top screen increases while amount on bottom decreases

Case 3. Improper Loading of Liquid Caused Variation In Moisture, Crude Protein and Ash (Mineral) Levels In The TMR Along the Bunk

Liquid Spray Bar 3” dia pvc, 4 to 6 feet long 1/2 “ dia holes 6 inches apart Cap ends and place holes in caps Two rows of holes positioned at 5 and 7 o’clock
Recommendations for liquid supplements in TMRs:
Highly recommend to suspend small particles and to reduce sorting
Make sure wagon is level during mixing
Use spray and load liquid over the center of mixer between screws or augers
Add liquid to commodity pre-blend
Make pre-blend and TMRs on the same day reduce heating and spoilage

Adding Liquid With A Spray Bar

Outline
What Is A TMR Audit
Managing Ingredient variation and shrink
Labor Efficiencies
Summary of Diamond V TMR Audit Data

Key Focus Areas for Managing Shrink and Nutrient Variation In Home Grown Ingredients

Silage Face Heating Source: Venne. 2007

Silage Temperature 6 hours after Facing 4:00 PM Source: Venne and Martel. 2008 No Facer Faced 12-18” Faced 24-36”

43.3 44.4 45.7 40.7 41.0 41.8 36.0 36.3 37.8 43.3 43.6 43.7 41.6 42.9 43.0 36.4 37.7 37.9 Haylage NDF – Sampling and Laboratory Consistency Evaluation Stone. 2008

Avoid Digging Into The Face

Excellent Face on Haylage Pile

Facing Haylage Pile

Pushing and Lifting Alfalfa Haylage Into A Pile

Crude Protein Levels In Haylage Sampled From the Face
Width of pile at base = 135’
10 Samples taken from face
Values, % of Dry Matter
23.8 24.5 20.0 23.0 20.1 19.4 19.4 23.7 24.1 17.4

Crude Protein Levels In Windrow After Haylage was Faced 23.0 22.4 21.4 18.9 19.3 18.3 18.4 20.1 23.1 21.1
10 equally spaced samples taken from windrow starting
10 feet from the edges of the pile
Windrow was 135’ long
Fresh haylage was avoided in sampling
Values, % of Dry Matter

Crude Protein Levels In Haylage Pile 21.9 19.4 22.0 21.6 21.9 19.8 20.1 19.4 21.4 20.3
Samples 4, 5 and 6 taken 3’ under surface
All other samples taken at surface
Values, % of dry matter

Silage Face Management Summary
Cut back plastic and place extra tires on leading edge
Remove spoiled silage as needed
Make silage face smooth and vertical
Blend faced silage into a pile to minimize variation in the silage and in the TMRs
No loose silage at end of feeding

Outline
Silage Facing Trial
Labor Efficiencies
Summary of Diamond V TMR Audits

Opportunity for Improved Efficiencies?

Reduced Mixing Time in Half Super Mix

Labor Efficiencies
Are the feeding facilities laid out to maximize quality & efficiency?
Have we observed our feeders mix?
Do We Communicate with our Feeders?

Outline
Silage Facing Trial
Reading Bunks
Labor Efficiencies
Summary of Diamond V TMR Audits

States Where TMR Audits On Lactation Rations Have Been Done TMR audits from CA and MI have not been included

Types of TMR Mixer Wagons Tested During TMR Audits HA = horizontal 4-auger HP = horizontal paddle HR = horizontal auger-reel V1 = single auger vertical V2 = twin auger vertical V3 = triple auger vertical Number of TMR loads tested: 514

Top 10 Brands of TMR Mixers Indentified in TMR Audit Summary Number of TMR loads tested: 514

Types of TMR Rations Tested In 514 Loads

Repeated TMR Audits Show Improved Consistency Over Time Data represents 75 out of 514 loads

Top 25% of TMRs have coefficients of variation of 3% or less Goal: 3% CV or less in middle and bottom screens of Penn State Shaker box

Coefficient of Variation Levels for TMR Consistency
</= 3%
Top 25% of TMRs
TMR mixing basics followed
excellent - mostly corn silage, haylage and/or chopped hay: easy to mix, new and well-maintained mixers
</= 4%
Top 50% of TMRs
Not sure cow performance is different from 3% CV
>4%
Antidotal evidence has show 1 to 3 lbs inc. in milk and improved milk fat% after corrections are made
Poor TMR Mixing Basics
Not mixing long enough after last ingredient
Overfilling
Worn augers and kicker plates
Hay not processed
Ingredient mix order not optimized
Liquid not loaded in proper position

Summary of What We Covered
What Is A TMR Audit
Silage Facing Trial
Labor Efficiencies
Summary of Diamond V TMR Data
Best mixer is one that is well maintained and managed by following TMR mixing basics

Managing TMR Variation

by DAIReXNET on Dec 05, 2011

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Managing TMR Variation — Presentation Transcript