In a compost bedded pack system, manure and urine are combined with bedding materials, such as straw or sawdust, within a roofed housing area. The mixture is mixed frequently using a tractor to introduce oxygen, increase moisture evaporation, and ensure a more uniform decomposition of both manure and bedding. Under these conditions, microorganisms decompose the manure and bedding mixture to create compost.
Fresh bedding is added as needed to maintain a proper balance between moisture and the carbon:nitrogen ratio, which is critical for optimal microbial activity. The compost bedded pack typically remains in place for 6 to 12 months, after which it is removed. The compost material is then applied to cropland or pasture.
Compost bedded packs are sometimes confused with bedded packs. In a traditional (anaerobic) bedded pack system, bedding is added regularly to absorb manure and urine, but the pack is left undisturbed, leading to slower decomposition. In contrast, an aerobic compost bedded pack undergoes frequent mixing, which improves oxygenation and microbial breakdown, resulting in faster and more complete decomposition. This produces higher-quality compost with enhanced nutrient stabilization, making it more beneficial for land application.
When used, in what regions in the U.S. is the practice found:
Northwest, Upper Midwest, Northeast
FARM SIZE
When used, typically found on farms of the following sizes:
Under 500 cows
Practice Benefits
Enhanced animal comfort: The bedding material provides a comfortable environment for the animals, which can improve their health and productivity. Studies suggest that compost bedded packs can enhance cow welfare by improving resting comfort and foot and leg health, allowing more natural behavior. Cows also stay in the herd longer because of less stress and injury.
Reduced labor and equipment costs: The compost bedded pack reduces the need for frequent manure removal and handling, which can save on labor and equipment costs.
Lower-cost barn construction: Compost bedded packs can be less expensive to construct than some other types of dairy housing. This is because they often do not require cement floors or extensive infrastructure, which can significantly reduce construction costs.
Reduced manure storage costs: Since the manure is managed as a solid and is "stored" directly under the cows, there are fewer requirements for separate manure storage facilities. This integration of storage and housing helps lower overall manure storage expenses.
Reduced manure volume: The volume of manure is reduced significantly, lowering the expense associated with manure spreading.
Odors: A properly managed compost bedded pack will have virtually no odors.
Implementation Insights
Site-specific or Farm-specific requirements
In most cases, there are no specific site or farm requirements.
Required Capital Expenditures (CapEx)
Building construction: The primary investment in a compost bedded pack system is the construction of a roofed barn or housing area. Since the pack’s height will increase as more bedding is added, wall heights must be sufficient to avoid overflow onto the barn floor. Additionally, the roof must be higher than standard barns to accommodate the increased pack height and allow adequate clearance above a full pack. This extra clearance contributes to better air circulation.
Tilling or turning equipment: Tilling or turning equipment must penetrate at least 12 to 18 inches to get oxygen further down into the pack. Field-type chisels will work. Power-driven tillers are also an option but may require more horsepower and maintenance.
Air circulation and ventilation systems: Ventilation can be achieved using roof vents or mechanical systems such as exhaust fans and circulation fans. Without proper ventilation, moisture can condense on the pack, causing it to become too wet and disrupting the composting process. While circulation fans help promote air movement and drying, they do not fully replace ventilation systems required to remove excess heat and moisture from the barn environment.
Bedding storage area: Another essential component of a compost bedded pack system is a dedicated storage area for bedding. This area should be located close to the production barn for easy access.
Required Operational Expenditures (OpEx)
Carbon-rich bedding: Carbon-rich bedding, such as straw, sawdust, or wood shavings, is regularly added to the compost bedded packs. The amount of bedding required can be significant, as it must be added frequently to maintain a proper carbon:nitrogen ratio, which is essential for effective composting. If bedding is not produced on the farm, sourcing and purchasing it can add substantial costs. Additionally, the time spent acquiring, transporting, and storing bedding materials must be factored into the ongoing operational costs.
Labor for tilling the pack: Daily tilling or turning of the compost bedded pack is required to maintain the aerobic environment needed for microbial activity. This process ensures that the compost remains oxygenated, promoting efficient decomposition. Tilling is often done while cows are in the milking parlor or a holding area, so the timing must be carefully coordinated.
Labor and equipment for pack removal: Over time, the compost bedded pack becomes compacted as the animals continue to use the space and as bedding is added. Typically, the pack is removed annually, requiring heavy equipment such as dump trucks, loaders, and excavation machinery to clear out the dense, compacted material. This removal process is labor-intensive and may need to be done in stages to allow time for the animals to be temporarily relocated. Farmers may also need to create a staging area for stockpiling the composted material before it is applied to fields.
Implementation Considerations
Changing pack height: A compost bedded pack system gradually increases in height as more bedding is added over time, which can introduce challenges in managing animal facilities. As the pack rises, various systems need adjustment to maintain optimal functionality. For instance, watering stations must adapt to the shifting pack height to ensure that cows can consistently access water without difficulty. In addition, the changing height of the pack creates a slope towards entrances and exits, which becomes steeper over time and may influence cow gait and footing.
Bedding quality and quantity: The effectiveness of the compost bedded pack system hinges on the proper management of bedding. Bedding that is too wet, often resulting from poor storage or sourcing, can create anaerobic conditions in the pack, leading to poor microbial activity, increased ammonia emissions, and inadequate composting. In contrast, too much bedding can over-dry the pack, stifling microbial decomposition. The balancing act of maintaining the proper carbon:nitrogen ratio and moisture content is critical, particularly in regions with high humidity or during winter months when moisture control is more difficult.
Udder health: While maintaining adequate udder health is possible, the high bacterial concentrations in the bedded pack necessitate proper management to ensure cow cleanliness and reduce mastitis risk. While composting processes help break down organic matter, they can also create conditions conducive to bacterial growth, which pose risks to cow health. Studies have shown that bacterial counts, particularly those associated with mastitis pathogens, tend to be higher in compost bedded packs compared to other bedding systems like sand or mattresses.
Cold temperatures: In colder areas, a temperature drop could result in the microorganisms dying off and causing housing conditions to deteriorate. Composting relies on thermophilic microorganisms operating best at higher temperatures (between 55°C and 65°C). When ambient temperatures drop, microbial activity slows down, reducing the decomposition rate and potentially leading to pack conditions unsuitable for cow comfort. In extreme cases, the pack may require more frequent bedding additions to compensate for reduced microbial action, or it may need to be cleaned out early to prevent poor housing conditions.
Financial Considerations and Revenue Streams
PROFIT POTENTIAL
Composted pack material can be sold if a buyer is available.
FINANCIAL RESOURCES, TOOLS, AND CASE STUDIES
Additional Resources
Article: Consider Bedded Pack Barns for Cow Comfort and Manure Management (Cornell University)
Report: Bedded Pack Survey Report (University of Vermont)
Scientific Article: Black, R. A., Taraba, J. L., Day, G. B., Damasceno, F. A., Newman, M. C., Akers, K. A., Wood, "The relationship between compost bedded pack performance, management, and bacterial counts"
Video: Composted Bedding Pack Barn (Farm & Food Care)
Website: Bedded Pack Barns for Cow Comfort and Winter Management (University of Vermont)
Website: Compost Bedded Pack Barns For Dairy Cows (University of Minnesota)
Environmental Impacts
MAY REDUCE FARM GREENHOUSE GAS FOOTPRINT
Compost bedded pack systems can reduce methane emissions compared to traditional anaerobic lagoon or liquid/slurry storage systems. Methane production is lower because the manure is stored in aerobic conditions, which inhibit the anaerobic processes responsible for methane generation. However, it is important to note that methane and ammonia emissions can still occur, particularly during warmer months, when microbial activity increases. Research by Fuertes et al. (2023) suggests that while methane emissions are lower than those from uncovered anaerobic lagoons, compost bedded packs may release significant amounts of methane and ammonia under certain conditions, especially when the pack becomes anaerobic or overly moist.
REFerences
Alignment with FARM Program
FARM Environmental Stewardship (ES) V2-V3 Alignment
FARM ES Version 3 includes a compost bedded pack barn as a housing type option in the manure section of the tool.
Contents
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We're always eager to update the website with the latest research, implementation insights, financial case studies, and emerging practices. Use the link above to share your insights.
In a compost bedded pack system, manure and urine are combined with bedding materials, such as straw or sawdust, within a roofed housing area. The mixture is mixed frequently using a tractor to introduce oxygen, increase moisture evaporation, and ensure a more uniform decomposition of both manure and bedding. Under these conditions, microorganisms decompose the manure and bedding mixture to create compost.
Fresh bedding is added as needed to maintain a proper balance between moisture and the carbon:nitrogen ratio, which is critical for optimal microbial activity. The compost bedded pack typically remains in place for 6 to 12 months, after which it is removed. The compost material is then applied to cropland or pasture.
Compost bedded packs are sometimes confused with bedded packs. In a traditional (anaerobic) bedded pack system, bedding is added regularly to absorb manure and urine, but the pack is left undisturbed, leading to slower decomposition. In contrast, an aerobic compost bedded pack undergoes frequent mixing, which improves oxygenation and microbial breakdown, resulting in faster and more complete decomposition. This produces higher-quality compost with enhanced nutrient stabilization, making it more beneficial for land application.
Practices and technologies
Compost Bedded Pack
alternative practice name:
Bed Pack