The Brief

FGS Pilcher undertook construction and enabling works to support the upgrade of dairy infrastructure at S.E. Lane & Partners, a working dairy farm in Kent. The project was part of a broader transition from smaller scale milking systems and robotic units to a higher-capacity milking solution. This shift was driven by increased herd size, greater production demands, and requirements for enhanced operational efficiency.

Previous systems had successfully reduced labour demand but had reached their capacity limits as herd output increased. This made upgraded infrastructure and improved cow flow management essential.

Scope of Works 

• Groundworks and site preparation for upgraded dairy infrastructure
• Formation of structural bases to support milking systems and associated equipment
• Construction works to accommodate revised livestock movement and operational layout
• Integration of access routes for cattle circulation and handling
• Coordination with specialist milking system suppliers

Key Constraints & Risks

Live Farm Environment
All works were carried out within an operational dairy farm with ongoing milking, feeding, and herd management activities.
System Integration
Construction works required coordination with specialist milking equipment and layouts.
Capacity Pressure
Existing infrastructure had reached operational limits, meaning downtime or delays would directly impact productivity.
Animal Welfare & Movement
Design and construction needed to support efficient, low-stress cow movement.

Delivery Approach

• Phased delivery to allow continued farm operation
• Controlled working zones to separate construction from livestock areas
• Close coordination with farm operators to align works with daily routines
• Progressive integration of new infrastructure alongside existing systems

Challenges & Lessons Learned

Challenge 1: Working Around Live Milking Operations
Issue: Construction activity had to be integrated alongside ongoing milking operations.
• Sequencing works around milking times
• Restricting access during peak operational periods
• Maintaining segregation between livestock and construction areas
Lesson Learned: Early alignment with operational schedules and flexible sequencing is critical.

Challenge 2: Existing System Capacity Constraints
Issue: The existing milking setup was operating at capacity, increasing sensitivity to disruption.
• Prioritisation of enabling works
• Minimisation of downtime during transition stages
Lesson Learned: Construction sequencing must prioritise operational continuity.

Challenge 3: Livestock Flow and Layout Efficiency
Issue: Existing layouts restricted cow movement and efficiency.
• Adjustments to layout during delivery
• Coordination with farm management
Lesson Learned: Design flexibility is required based on real livestock behaviour.

Outcome

The upgraded dairy infrastructure supports improved operational efficiency, enhanced livestock
management, and increased system capacity.