We began with thorough research on modern milking parlors to understand optimal cow flow, ergonomic considerations, and load requirements. The design development began with the client’s initial inputs and reference drawings.
Based on these requirements, we developed two variants:
- double-parlor (parallel) system, and
- rotary-parlor system
This gave the client flexibility to choose the layout that best fits their space, capacity needs, and operational workflow.
We prepared the detailed design and built a complete 3D model of each structure, ensuring that all components worked together efficiently. This work was part of our structural engineering design services, delivering precise, performance-driven solutions tailored to the client’s operational needs.
Here’s our step-by-step process:
1. Layout Preparation and Design Planning
We began with a detailed layout to define cow flow, operator movement, and equipment zones. This helped us visualize the full milking sequence for both variants.
- Created a precise 2D CAD layout based on reference drawings and customized the entry/exit arrangement.
- Verified ergonomic spacing to ensure smooth, stress-free cow movement in both parallel lanes and rotary loading zones.
- Identified structural support points, load paths, and clearances early to streamline 3D modeling.
2. Structural Frame Design
Once the layout was approved, we developed the primary supporting structure for both parlor types.
- Modeled frames, beams, and columns in 3D CAD using standard steel sections for easier fabrication.
- Validated cow entry/exit paths—including rotary deck approach paths—to ensure unobstructed movement.
- Standardized joints and member profiles for quicker welding and consistent manufacturability.
Parallel and rotary structures required different load considerations, so the platform, deck supports, and stall alignment geometry were analyzed separately.
3. Side Panels, Stall Dividers & Safety Components
Animal comfort and hygiene were core considerations for both systems.
- Designed smooth, rounded dividers with no sharp edges.
- Included adjustable mounts for different cattle sizes and better cleaning access.
- Maintained uniform geometry to reduce fabrication complexity and inventory.
These parts were designed for durability while supporting high-throughput dairy operations.
4. Automated Entry Gate (Double-Parlor System)
For the parallel system, we developed an automated entry gate for synchronized cow loading.
- Pneumatic + spring-assisted actuation for quiet, low-stress operation.
- Strength-checked gate arms for impact loads during crowd movement.
- Manual override included for safety and maintenance.
- Designed for seamless integration with future automation controls.
This helped improve throughput in high-volume milking cycles.
5. Rapid Exit Vertical Lift System (Double-Parlor)
To speed up batch turnover, we engineered a synchronized rapid-exit mechanism.
- Designed linkages for uniform lifting of all front gates.
- Optimized actuator placement to reduce power draw and extend component life.
- Validated movement to ensure smooth, jam-free operation.
This system significantly reduces cycle time for double-parlor operations.
6. Rotary Milking Parlor - Platform, Stalls & Cow-Pusher Design
The rotary variant required a different engineering approach since cows load continuously.
Rotary platform & structural deck
- Developed a rotating platform capable of supporting continuous movement and multiple cow loads.
- Analyzed radial and torsional loads to ensure long-term stability.
- Designed stall alignment geometry so cows load smoothly at the entry point.
Automated cow-pusher system
Rotary parlors don’t use entry gates or rapid-exit lifts. Instead, loading happens one cow at a time.
- Designed an automated cow-pusher mechanism to guide cows into each stall as the deck rotates.
- Timed the pusher movement with platform rotation for consistent flow.
- Ensured gentle, low-stress handling to maintain animal welfare.
7. Mechanical & Automation Integration
Both variants required precise structural provisions for milking equipment and controls.
- Added mounting points for milking clusters, pulsation lines, sensors, wash-down systems, and control enclosures.
- Ensured vibration clearance for pumps and pipelines.
- Designed cable routing and maintenance access for easy servicing.
This ensured compatibility with modern dairy automation systems.
8. Material Selection & Compliance
Materials were selected for durability, hygiene, and compliance with US dairy engineering standards.
- All materials selected as per ASTM standards, ensuring safety, weldability, and corrosion resistance.
- GI steel for primary structures to balance strength and cost.
- SS304/SS316 for panels, gates, and components exposed to moisture and chemicals.
These choices ensured long service life and reduced maintenance requirements.
8. Design Validation and Detailing
Once the full model was complete, we performed detailed validation checks.
- Checked all components against static and dynamic loads: cow weight, gate operation, rotary motion, etc.
- Ensured structural compliance with AISC steel design standards and ASCE 7 load requirements.
- Verified operational safety based on USDA animal welfare guidelines and OSHA standards.
Sedin Engineering structural design team delivered detailed fabrication drawings, assembly instructions, and a complete bill of materials. This provided the client with a manufacturing-ready, installation-ready design package.
