The Gist: Jersey Girl farm near Winton upgraded their composting barn to a Numat-built covered feed pad with flood wash and Siesta rubber mats in May 2024. This delivers drier cows, slashed labour, and serious savings.
You gain 5 hours of staff time daily, cut woodchip and tractor costs entirely, and boost ROI through healthier hooves and higher productivity in a 900-cow herd. This system pays back fast in New Zealand’s tough weather.
Project Snapshot:
- Herd Size: 900 purebred Jersey cows.
- Build Delivered: May 2024
- Barn Setup: Two barns, each 26m wide with a 1.7% slope for seamless drainage.
- Flood Wash Specs: 60,000 litres of greenwash water per barn flush, completed in under 5 minutes, One to three times daily.
- Storage System: Two interconnected 30,000-litre tanks for water release, plus a 160,000-litre sump capturing effluent for reuse.
- Labour Savings: 5 hours per day – over 1,800 hours annually for your team.
- Cost Reductions: Eliminates woodchip expenses ($35-$50 m3 depending on region), lowers tractor fuel and maintenance, and drops vet bills from reduced lameness.
- Square metres covered in rubber mats: 4,687.6 m²
- Rubber mats: 2,363
- Investment value: Circa $1,5m + earthworks
Numat Construction handled the full conversion from existing composting barns, ripping out old setups and installing Siesta rubber mats for long-term durability.
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Finding the Right Fit for Southland Conditions
Jersey Girl farm milks 900 Jerseys in Southland’s harsh climate. While composting barns work well on some farms, the owners found it wasn’t the best fit for their conditions. Cold temps, high winds, and heavy rain made it difficult to keep the bedding dry and comfortable for cows.
Daily maintenance and regular top-ups added to the workload and costs, and the wet surface increased the risk of slipping. Having previously wintered cows on crops, they’d already seen the impact mud could have on hooves and animal comfort.
Every farm is different, and the smart move was to adapt with a standoff pad system better suited to their environment; one that could protect pastures, ensure compliance, and keep cows productive through winter.
Numat’s Custom Covered Feed Pad with Flood Wash and Siesta Rubber Mats
Numat Construction transformed their setup into a high-performance feed pad. We replaced compost with Siesta rubber mats – soft, non-slip surfaces from recycled tyres that cushion hooves and last 20+ years.
The flood wash system is the game-changer: Water releases from risers every 65mm, creating a cleaning wave across the 1.7% sloped barns. The greenwash flows to the sump, passes through a weeping wall to separate solids, then gets pumped back for reuse—reducing nitrogen leaching and working seamlessly with existing ponds. This flood washing setup integrates seamlessly with dairy rubber matting, making it simple and low-effort.
We handled the full build – ripping out old composting elements, grading for slope, installing tanks and mats.
Easier Operations and Bottom-Line Wins
The upgrade delivered an immediate impact at Jersey Girl.
- Cows stay dry and clean all winter, lounging happily on Siesta mats without mud or slips.
- Flood washes three times a day keep surfaces spotless, with no manual scraping needed.
- Effluent management is efficient – captured, stored, and reused without waste.
- Labour dropped by 5 hours daily, allowing staff to put energy into the rest of the farm.
- No more woodchip bills or tractor hours for tilling.
- Vet costs fell from better hoof health and reduced injuries.
For a 900-cow operation, this means thousands saved yearly, with ROI often hitting in 3-5 years through higher milk solids and lower overheads.
Straight Talk from Jason and Leanne Erb
Jason and Leanne Erb shared their experience in our video. Their words confirm the transformation.
"We were looking for something better"
"A lot less time spent working in the winter time compared to composting. 5 hours a day it saved our staff."
"The animal health has been quite big as well. The cows are a lot happier in barns."
"It seems to be lasting pretty well. I can't really say I've noticed any wear spots."
"The cows are dry all winter. It's really nice. You can go in there, walk around them. They're as happy as Larry. Yeah, it's a good feeling knowing you're looking after your stock."
These real Kiwi farmer insights show how flood wash feed pads and rubber mats deliver what you need.
This system fits any dairy farm seeking durable, ROI-driven solutions. Numat builds these to last in NZ conditions, giving you peace of mind season after season.
See the system in action, get in touch and we can arrange a visit to the Jersey Girl farm.
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