Farmers reap benefits of tailored GEA batch milking system

GEA recently launched its batch milking system, DairyRobot R9650, a solution that adapts to individual farms, their herds and farmers’ daily routines. It combines the structure and predictability of group milking with automation and digitalization. This enables precision livestock management, smoother routines and resource-efficient dairy farming.

A system that adapts to the farm

The dairy cooperative Diedorf is tucked into a hillside in the Thuringia state of central Germany. Andrea Ochsenfahrt manages the cooperative’s 300-cow farm with a broader team of which 3 dedicated colleagues take care of the milking. Diedorf was never built with robots in mind; that was exactly the point when the farm’s management began thinking about modernization and automation. “We were looking for more efficiency, calmer routines and fewer labor demands, but without building new facilities,” explains Andrea Ochsenfahrt.

Working closely with their local dealer and GEA specialists, the Diedorf team reconfigured their daily milking routine, adopting automated group milking with GEA’s DairyRobot R9650. The upgrade allowed for the integration of the parlor in the existing barn, carefully adapted to the slope, the original workflow and space constraints. This tailored approach enabled Diedorf to maintain their original milking schedules.

This batch milking implementation was not merely driven by a technology upgrade, but by a clear philosophy: keep what works, improve what doesn’t and respect the unique set up and layout of the farm.

Subway design makes efficient use of space

The DairyRobot R9650 from GEA builds on years of batch-milking experience. It takes advantage of individual-quarter milking, 3D-teat detection, in-liner everything from teat cleaning to dipping and integrated sensors to ensure milk quality and cow welfare. But what clearly stands out is the solution’s “subway” design which means key components are housed centrally underneath the robot, including the milk receivers, valves and milking modules. This design makes the most of limited space while promoting a calm barn environment and allowing for easier maintenance.

In Diedorf, the subway design was key to fitting the modern automation system into an existing building. The result: the cows move calmly through the boxes, while below the dealer can service the system easily and safely. By dividing the space, the existing barn layout is maintained while noise levels are lower, and the cows are more comfortable.

“Most of the technology is down here,” explains service technician, Alexander Cott, from the local GEA dealership FFI. “For service, it’s perfect. Everything is accessible and clean. And upstairs, the difference in noise and atmosphere is remarkable.”

Efficiency at scale for larger dairy herds

While Diedorf is a story about integration, the Kotopoulos farm in northern Greece is a very different example of what batch milking can achieve for dairy farmers. Here, the system was not required to adapt to existing structures. Instead, the farm was designed from scratch, with a clear vision of scale, efficiency and resource management.

At Kotopoulos, 20 milking boxes operate in carefully coordinated batches. Hundreds of cows move calmly through their daily routine, guided by group schedules that reduce waiting times and create a predictable rhythm for both animals and staff.

Where other systems might struggle with complexity at this size, the DairyRobot R9650’s layout creates simplicity. A single central receiver handles milk from up to 12 boxes. This reduces parts, maintenance, electricity and water consumption – and requires fewer consumables compared to systems where each box has its own receiver and milk pump. Here the entire system is structured around minimizing effort and maximizing clarity.

Visitors often describe their first impression the same way: Despite its size, the farm feels calm. Workers move through the barn with quiet routine; cows walk in steady batches; the equipment runs with steady precision. Every detail, from the layout of the subway cellar to the configuration of milking groups is designed to make large-scale milking manageable and resource efficient.

Behind the scenes, the DairyNet herd management system provides the digital backbone. Live box status, animal data, alerts and trend analysis are available on mobile devices, keeping operators informed wherever they are; this enables them to take faster and better decisions and maintain an overview.

A new rhythm for modern dairy farming

Batch milking with the R9650 offers something that single-box or rotary systems cannot always provide: the opportunity to keep the familiarity of group milking, but with the precision and data transparency of modern automation. For some farms, that means integrating technology into buildings shaped by years of experience. For others, it means designing a new facility that can manage hundreds of cows with clarity and consistency. In each case, the system adapts to the herd, the people and their daily routine. Because efficiency is not just about doing more. It’s about doing things in a way that works holistically.