In the world of dairy barn design, one size doesn’t fit all. Every barn comes with its own unique set of challenges, especially when it comes to managing ventilation. However, as dairy operations grow in size and complexity, the need for standardized design principles becomes more apparent. This is where Dr. Mario Mondaca’s work in barn ventilation design has made a significant impact. Dr. Mondaca, an expert in biosystems engineering, has spent much of his career focusing on understanding how different barn designs affect the airflow and, ultimately, cow comfort and productivity. His journey to parametrize barns—essentially creating standardized design categories that streamline ventilation design—has led to breakthroughs in making dairy barn design more accessible and efficient.

The Challenge of Standardizing Dairy Barn Design

Dr. Mondaca began with his realization that dairy barns, though varied in structure, could still be classified based on key parameters that directly influenced ventilation effectiveness. “There are many factors that make each dairy barn ‘special,’” Dr. Mondaca explains, “but when we step back and look at the barn as a system, we can start categorizing the most important design features that have a measurable impact on ventilation.” As a postdoctoral researcher, Dr. Mondaca worked to formalize the recommendations around dairy ventilation, which were often inconsistent or conflicting. While many experts had ideas about what made for effective barn ventilation, there wasn’t a clear, standardized methodology for designing systems that catered to the specific needs of dairy barns. “There wasn’t a very clear path of what makes good ventilation design,” says Dr. Mondaca. “My role was to bring some consistency to the recommendations and create a solid framework for ventilation assessment and barn design.”

Key Facility Parameters and Their Impact on Ventilation

In his research, Dr. Mondaca identified several key barn parameters that were crucial to effective ventilation design. He categorized these parameters to simplify the often complex barn configurations, helping to create a standardized approach to ventilation. These parameters include:

1. Barn Layout The arrangement of pens, lanes, and feeding areas in the barn is essential to how air circulates throughout the space. The width and depth of the barn, as well as the number of pens, can directly affect air distribution and flow. Dr. Mondaca focused on understanding how different barn shapes—such as three-row pens or head-to-head pens—impacted airflow and how to optimize fan placement and ventilation systems for each design.
2. Animal Occupied Zones vs. Shared Zones Dr. Mondaca classified barns into Animal Occupied Zones (where cows are housed) and Shared Zones (such as transfer lanes and feed alleys). These zones have different ventilation needs. Cows in the pens generate heat, which needs to be managed through adequate airflow, while other parts of the barn, like the feeding or milking areas, may require different ventilation setups. Understanding these distinct zones helps refine the design for optimal air circulation.
3. Pen Type and Configuration The type of pens used (e.g., three-row, head-to-head, or single-row pens) plays a significant role in how air flows through the barn. Dr. Mondaca found that barn designs could be classified by the width and depth of pens, influencing the spacing and placement of fans. By recognizing these patterns, he could design more efficient ventilation systems tailored to the specific needs of each barn configuration.
4. Transfer Lane Design Transfer lanes, or the areas where cows move between different parts of the barn, also influence airflow. Whether these lanes are placed at the center of the barn or along the edge, the position affects how fresh air enters the barn and how exhaust air is removed. The positioning of transfer lanes also impacts fan placement and system efficiency.

Standardizing Barn Design: The Key to Efficient Ventilation

Dr. Mondaca’s work led to the development of an abstract mathematical model that quantifies the relationship between barn layout and ventilation efficiency. He created a parametric approach to barn design, which allowed for high-level descriptions of barns using a few key identifiers. For example, by knowing the width of the barn, the number of pens, and whether the transfer lanes are in the center or on the edge, the ventilation system could be customized and optimized. By standardizing these parameters, Dr. Mondaca created a prototype tool that could generate barn layouts based on input variables, automatically calculating the number of fans required and the ideal fan placement for the barn. This model simplified the complex process of designing a barn and enabled quicker, more efficient decision-making.

Applying the Research: From Theory to Practice

Dr. Mondaca’s research didn’t stop at theory. His work has had a tangible impact on dairy barn design. By applying these standardized principles, dairy farmers and builders now have access to tools that help them design barns with optimal ventilation without needing a deep understanding of complex ventilation systems. For example, through VES-Artex’s CPQ (Configure, Price, Quote) tool, Dr. Mondaca and his team have streamlined the sales process for barn design. This tool allows dealers and producers to input basic information about their barn—such as herd size and barn dimensions—and receive a custom ventilation solution complete with fan specifications and associated costs, without lengthy back-and-forth communication. This approach has sped up the design process and made it more accessible for dairy producers.

The Future of Dairy Barn Ventilation

Dr. Mondaca envisions a future where standardized designs for dairy barns become the norm. By leveraging research and tools like the CPQ tool, the dairy industry can move toward more consistent and efficient barn designs. However, he also acknowledges that every barn is unique. “There’s no such thing as a one-size-fits-all solution,” he says, “but by categorizing barns into high-level, consistent parameters, we can create designs that are both effective and adaptable.” Dr. Mondaca’s work has laid the groundwork for research-driven ventilation design, where the focus is not only on cow welfare but also on creating barns that are more energy-efficient, cost-effective, and easy to maintain. To see Dr. Mondaca’s complete presentation, click here. To design your future dairy barn, please contact us or your closest VES-Artex dealer!