The big composting barn at Willesden Farms is complete and already proving its worth in action. This large-scale facility is now fully operational and housing cows. The design is set to cut the farm’s environmental footprint by 46%. It protects pasture, boosts animal welfare, simplifies feed management and delivers long-term cost savings.
The barn holds 3,500m³ of woodchip bedding. It can comfortably feed up to 1,000 cows at once. This setup reduces stress during extreme weather, giving farmers peace of mind in wet winters or hot summers.
Press coverage highlights its innovative approach, and we are developing a detailed case study that will be released soon. YES, it’s a win for compliance and sustainability.
Dairy News spotlights Willesden’s composting barn success. Brent Thomas nails it: “It’s a formula that will vastly reduce the farm’s footprint while ensuring financial viability.” [Check the full story here]
From Vision to Barn: Collaboration and Key Specs
Composting barns represent a smart shift in dairy farming. They provide a controlled environment where cows rest on a bed of composting material. Composting feed barn captures animal effluent and helps preserve the pasture.
The collaboration started with Willesden’s vision. They wanted a barn that fit their specific needs on Banks Peninsula. Numat Construction brought expertise in design and build. Together, we tailored the layout for optimal cow flow and efficiency. The result is a durable structure built to New Zealand conditions where environmental and financial sustainability are linked.
YES, it directly addresses winter pugging and summer heat stress. No more worrying about soil erosion or heat-related productivity drops.
The Numbers: Size, Scale, and Smart Design
Let’s look at the numbers. The barn measures 185 meters long by 31 meters wide. That’s enough space for 550 cows to lie down comfortably. Feeding capacity for up to 1,000 cows allows for full herd nutrition inside, reducing reliance on outdoor grazing during bad weather. Farmers see improved milk yields as cows stay calm and rested.
Building the barn involved careful planning. Site preparation ensured stable foundations. Numat Construction managed everything from design to installation. The farmer’s input made it practical for daily use. Peace of mind is a big draw. In winter, heavy rain can turn paddocks into mud. Cows slip, leading to higher lameness rates. With the barn, herds stay dry and safe. Summer heat waves are handled too, with shade and ventilation preventing stress. Farmers report less worry about weather forecasts. Operations run smoothly, year-round.
Animal welfare improves. Cows on compost beds experience softer surfaces. This cuts down on hoof issues and joint strain. Reduction in lameness is a key outcome, leading to healthier, more productive herds. Pasture protection ties in directly. Keeping cows indoors during wet periods prevents soil compaction.
YES, it extends pasture life and boosts regrowth. Willesden Farms expects better grass quality, supporting higher stocking rates without environmental harm.
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Future-Proof Your Farm: Trends, ROI, and Real Recognition
The project aligns with broader trends in New Zealand dairy. Regulations push for lower emissions. Composting barns help meet these without sacrificing output. Numat Construction’s experience ensures builds are cost-effective. Up to 20% more cost-effective than traditional builds. At Willesden, the investment pays back through savings in maintenance and higher productivity. Collaboration was key throughout. The farmer shared insights on their needs and research. Numat adjusted designs for better flow and efficiency. End result: a barn that feels custom-built.
Press recognition validates the approach. The Dairy News article praises the 46% reduction. It notes how the barn cuts methane and nitrate outputs. Quotes from Brent Thomas and Matt Iremonger emphasize practical gains, like easier management. This exposure highlights Numat’s role in innovative farming.
Our full case study drops soon with timelines, challenges, an interview with Matt Iremonger, and hard outcomes. Stay tuned for that on our website.
Durability matters, the barn is engineered for 50+ years of service. Low maintenance keeps costs down. Consider the operational side. Feeding in the barn means precise nutrition control. Cows get consistent diets, boosting milk solids. In hot summers, shade prevents heat stress drops in production. Winter benefits are equally strong. No more shifting herds to distant paddocks. Everything stays on-farm. Peace of mind comes from knowing your herd is protected.
Sustainability isn’t just a buzzword here. The 46% reduction is calculated from baseline emissions. This positions Willesden as a model for others.
Full-Service Builds That Deliver
Numat Construction handles full-service projects. From concept to handover, we manage it. Our team collaborates to match your farm’s needs. Whether it’s a composting barn or feed pad, we deliver.
This project shows what’s possible. Large-scale, yet tailored. YES, it reduces environmental impact while enhancing welfare. Farmers facing similar challenges can benefit. Integration with existing infrastructure was seamless. The barn connects to the milking shed. Cow flow is optimized, saving time during routines. Long-term ROI is clear.
As New Zealand farming evolves, projects like this lead the way.
NuSpan barns are designed to be simple and cost-effective, offering a reliable, eco-friendly alternative to steel-framed barns. With quick lead times and easy installation, NuSpan puts control of your investment back in your hands.
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