Farm Ownership

Vir-Clair is owned by Gary and Rose Boyke

They are pictured here with their children, Katie (Grant), J.R., Angie (Ryan), and Tiffany

Where it all began…

� Vir-Clar Farms began in 1949 when Gary’s parents purchased the farm from his grandparents.

� They milked 13 Guernsey cows and rented a bull.

� In 1950 the farm purchased a registered Holstein calf.

The First Expansion

� Gary joined the operation in 1974 and the herd size was doubled to 60 cows.

� The herd remained the same size from 1974-1995.

� The focus through these years was on genetics. Vir-Clar put over 100 bulls in A.I.

The Herd Grows Again

� In 1995, Gary and Rose bought out Gary’s parents and expanded the herd to 300 cows.

� A new free-stall barn was built.

� In 1997, they added another 200 cows, and changed the parlor from a double 8 to a double 10.

Today at Vir-Clar

� 1,180 cows milking, 1350 total

� 27,619 rolling herd average

� Butterfat 3.71 Protein 3.07

� Milk shipped to Grande Cheese

� 65 % Registered

Arial View of Vir-Clar

� Photo of 2005 Fond du Lac County Breakfast on the Farm

� Last free-stall barn under construction in the background

Main Milking Parlor

� Double 20

Westphalia Surge

� ID as cows enter the

parlor

� 3x per day milking

� Dairy Comp 305

software is used to

manage the herd

� Labor efficient

Free Stall Barns

Mixing fans and sprinklers

Bedding: digested/separated solids

� First Barn

� 6 rows, 740 stalls

� 107’ x 408’

� Curtain sided, natural ventilation

� Second Barn

� 6 rows, 680 stalls

� 125’ x 708’

� Curtain sided, tunnel ventilation

Calving Pens

� 6 Individual pens for calving.

� Cleaned and disinfected between cows.

� Note fans on back wall for tunnel ventilation.

Herdsman Office

� Office located above animals for observation.

� Large windows allow for constant monitoring.

� Area contains the computer for tracking cow data.

Methane Digester

� Three years of planning.

� Location of the farm to residential was a determining factor.

� Goal was to reduce odor and be on the cutting edge of technology.

The Process - 1

� Cows consume ration consisting of fiber, protein, vitamins and minerals.

The Process - 2

� Cows digest ration and manure is excreted.

The Process - 3

� Automatic scraper pulls manure to the end of the barn.

� Cows easily step over the scraper.

� Manure falls into concrete holding area below the floor.

The Process - 4

� Manure is pumped from free-stall barns to

Digesters.

The Process - 5

� Manure is stirred and heated.

� Methane gas is produced and captured under

the inflatable roof.

� Manure can be transferred between tanks.

The Process - 6

� Gas is pulled from the digester and is burned as the only

fuel source for a Caterpillar engine.

� The engine then powers a high capacity generator.

The Process - 7

� Manure is gravity fed to separator building.

� Moisture is removed from the manure and new bedding

is conveyed to storage pile.

� Separated solids are used as bedding for the cows.

Digester Summary

� Four ways of value

� Electricity sold – today over 300 homes

� Separated solids used for bedding

� Separated solids sold to other producers for

bedding

� Less manure hauling expense

THANK YOU