Virtual tour

Join us on a virtual tour of Hülsenberg Estate.

 

Please click on the image captions to visit the various stops on our tour.

Karte mit Beraterregionen
CHP 250 kW
250 kW satellite CHP plant – yet another step towards environmentally friendly heat and power generation
250 kW satellite CHP plant – yet another step towards environmentally friendly heat and power generation

250 kW satellite CHP plant

The commissioning of our satellite CHP plant for the biogas plant on Hülsenberg Estate in 2011 constituted yet another step towards environmentally friendly power and heat generation.
With its 250 kW power output, the new CHP plant extends the capacity of our research biogas plant to a total of 776 KWel.

The plant is about 600 m from the actual research biogas plant. Its generated heat is used to supply a residential development.

Satellite CHP plants are decoupled from biogas production to ensure that waste heat can be utilised most effectively at the site of its consumption.

As heat is almost fully utilised and the process relies on the liquid manure produced on the estate, the estate’s overall environmental record is improved even further through this approach.

Concentrate silo plant
New silo plant constructed in 2015
Automated silo plant
Remote-controlled metering for superior precision
Vehicle loading

Concentrate silo plant

The new silo plant for concentrate was commissioned in June 2015.

Machines/workshop
Modern, own fleet
Regular checks ensure high availability of machines and vehicles
Tractor maintenance
Self-propelled mixer wagon

Machines/workshop

On Hülsenberg Estate, all works except forage harvesting and crop protection are completed under our own management with our own fleet.

ISF calves stables
Modern calf barn for research into optimum feed and husbandry conditions
Feeder with two stations
Optimal feed for healthy development
Tasty and enjoyable
Weight gain desired – calf scales for monitoring healthy feeds
Comfortable cubicles with adjustable flaps for resting
Looking forward to the day’s excitement
Dreaming about the next yummy feed

ISF feeding studies

On Hülsenberg Estate, ISF Schaumann Research operates and manages barns and capacities for feeding studies with up to 800 broilers, 80 calves, 200 piglets and 400 pigs for fattening. New additives and feeding concepts are evaluated here.

Training/canteen
Outdoor area for socialising

Training/canteen

Over several decades, Hülsenberg Estate was gradually developed into an internationally renowned research and communication centre.
Hülsenberg Estate serves as a venue for seminars and training events that allows participants to gain valuable direct insights into the operating conditions of a working farm.

Conference room

Conference room

Hülsenberg Estate and ISF Schaumann Research are popular destinations for visits by clients, scientists, suppliers and employees wishing to experience first-hand how our research and development work is done.

Cows II
Modernised freestall system with 105 cubicles and three large calving cubicles
Optimum environment for practice-oriented feeding concepts
Cows on feed fences
Lactating cows on their way to our modern milking parlour
Mother cow and newborn calf resting in the deep-litter calving cubicle

Cows II – 2 x single-row freestall system

The combined single/two-row freestall system, which was modernised in 2012, comprises 105 beds. These are designed as raised cubicles with comfort mattresses.

A new roof cover with insulated trapezoidal sheets was installed as part of the refurbishments. The old double-brick external wall was removed and replaced by blinds installed underneath the roof. The water supply was also renewed in its entirety.

This barn houses a lactating group of 60 cows; there is also a separate group for cows with conspicuous cell counts, which are milked last.

Animals that have been separated from the group can additionally be tied up at 21 feed fence positions. The remaining cubicles are available for dry cows. An additional three deep-litter cubicles have been established for calving cows.

 

ISF/Hülsenberg Estate Admin-istration
ISF/Hülsenberg Estate Administration
Administration, strategy and planning are teamwork
Well organised and always on the go – the Hülsenberg Estate management

ISF/Hülsenberg Estate Administration

Hülsenberg Estate is a modern farming operation with about 210 dairy cows and 2 biogas trial plants that provides an ideal forum for testing directly whether new methods and innovative products can be usefully transferred to practice.
Hülsenberg Estate has also been home to ISF Schaumann Research since mid-2013. The collaboration between research and practice encompasses supply to and disposal from the various segments in which we work, including silage, trial facilities, building management and heat supply.

Technology Centre
Technology Centre with rooftop solar panels for optimum use of roof surfaces
Entry to the laboratory and Technology Centre
Digester with continuous fermenters (24 units with 20 l effective volume each)
Biogas trial at a 1 l scale via pressure sensor with automatic gas discharge
Determination of temperature increases in silage to determine aerobic stability

ISF-Technikum

The new building of ISF Schaumann Research on Hülsenberg Estate comprises a 500 m² Technology Centre and biogas trial space.

The Technology Centre allows various large-scale trials to be conducted and processes to be tested.

-Ensiling trials (20 ºC climatic chamber)
-Determination of aerobic stability (20 ºC climatic chamber)
-Biogas batch trials (40 ºC climatic chamber)
-Biogas continuous trials (40 ºC climatic chamber)
-Mixing trials for acid granules and mixed feeds
-Technology Centre operation – eccentric vibrating mill for organic trace element production

 

ISF - Laboratory
Front of the laboratory and Technology Centre
Welcome to our laboratory tour
Modern laboratory tract
Receipt and preparation of samples
Chemical analytics – analysis of protein, nitrogen and ammonia
Fermentation acid/alcohol analyses using HPLC
Bulk and trace element analyses using ICP OES
Microbiological analytics for analysing moulds and yeasts
Drying of grass and maize silage samples

ISF laboratory

At the Hülsenberg Estate, ISF Schaumann Forschung conducts investigations for the development and approval of new feed additives.

The analysis focuses on animal feed, silages, organically bound trace elements, minerals, additional products for biogas fermenters and preserving acids.

The studies range from chemical and microbiological studies to physical and technical analyses in practical tests.

Latest analysis equipment and apparatus will be used in the 2013 new built laboratory and technology centre for laboratory analysis at the Hülsenberg Estate.
 

Heifer barn
Modern, animal-friendly refurbished barn for 134 heifers
Heifer feeding with special cattle rations
Animal welfare is our priority in successful heifer rearing
Cubicles are designed as raised cubicles with 3 cm rubber mat flooring
Thorough cleaning for greater animal comfort

Heifer barn

The 134 cubicles in our heifer barn, which was renovated in 2012, provide optimum conditions for rearing healthy heifers from about five months of age.

The outside walls were completely removed as part of the refurbishment and replaced by blinds. The cubicles are designed as raised cubicles with 3 cm rubber mat flooring. A new, frost-free water supply was installed underneath the gables.

The heifers are given feed remaining from the dairy cow herd up to 10 months of age and fed special cattle rations after. These consist of 6.5 kg grass silage, 1.1 kg maize silage, 1.5 kg straw and 90 g mineral feed (10 MJ NEL and 146 g crude protein per kg DM).

Multi-purpose hall

Multi-purpose hall for field work

This hall, which has a floor space of about 2000 m2, serves as a store for our field work department, including for feedstuffs and straw, among others.
Field work on Hülsenberg Estate includes animal husbandry, management of barn waste and responsibility for feeding, liquid manure and repairs. All works except forage harvesting and crop protection are completed under our own management with our own fleet.

75 kW liquid manure biogas plant
Biogas plant for fermenting liquid cattle manure
Regular checks ensure smooth operation
Monitoring of the fermentation process

75 kW liquid manure biogas plant

Solely for fermenting liquid cattle manure

The key features of this plant include a system for recovering heat from spent slurry and the installation of special non-woven mats in the fermenter’s gas holder to implement a desulphurisation system.

Utilisation of liquid manure offers potential for emission control and energy utilisation

Utilising liquid manure in the biogas plant achieves a range of positive effects. Part of the liquid manure is, for example, stored in gas-tight tanks to prevent considerable emissions of gas into the air. Anaerobic fermentation of liquid manure in the biogas plant additionally supplies energy that is used by the estate itself and fed into the public grid. Another advantage lies in the improved availability of nutrients from fermented liquid manure, which makes its use as organic fertiliser in forage production more effective and thus returns the manure to the system.

Renewable energy biogas plant
Climate-friendly biogas plant for renewable raw materials
Automatic supply via solids dispensers
Two identical fermentation streams for trials on a practically viable scale

Renewable energy biogas plant

526 kW power output and 250 kW power output via a satellite CHP plant
Hülsenberg Estate comprises a 776 kW field test biogas plant in order to be able to test whether the results of model trials can be applied to practical biogas production.
Two identical fermentation streams allow one trial variant each to be compared with a control variant on a practically viable scale.

Biogas silo plant
Silo filling with silage maize
Spreading of silage
Maize silage headline

Biogas silo plant

Forage silo plant
Grass silage
Grass silage headline
Forage chopper on Hülsenberg Estate
Rotary cutting of grass silage
Filling of the mixer wagon with grass silage

Forage silo plant

Calf barn
Unit of 3 single calf boxes
Calf in a single box
Group pens with straw bedding
Group pen with feeder buckets and covered shelter
Calves in group pens with straw bedding
Calf pen with open shelter
Highest priority for animal welfare
Calf feeder

Calf barn

A new barn providing space for 100 calves in three different sections was built in 2013.

  • Newborn calves are kept in single boxes organised in units of three until they are 14 days old. These boxes, which can be moved around on rollers, are located at the outside of the barn. The calves are fed colostrum for the first four days and then up to 6 l liquid feed with 150 g calf milk replacer powder per litre of feed until 14 days of age. Calf pellets are offered as solid feed even at this early stage.
  • At 15 days of age, calves are transferred to group pens with straw bedding, where they are fed from buckets filled from a Milk Taxi. Here, the daily liquid feed ration is increased to 7 l, and calf TMR is offered as well. From 56 days of age, calves are additionally given the same fresh TMR fed to dairy cows.
  • Calves are then transferred to a cubicle section with rubber mat flooring. The cubicles are always stocked using an all-in/all-out approach for hygienic reasons. From 7 months of age, the heifers are finally moved to the freestall system for our cows.
Milking centre
Cows on their way to the milking parlour
2 x 12 side-by-side-milking parlour
The average daily yield is just under 36 kg milk.
High lifetime productivity of 19 kg milk/day of life for sustainable milk production
High lifetime productivity per day of life is indicative of excellent animal health on Hülsenberg Estate

Milking centre

Our dairy herd with 210 cows producing about 11,500 kg milk per animal and year forms the core of our dairy operations. The lifetime yield produced by our cows is exceptionally high, with about 38,000 kg.

The herd is milked in a side-by-side 2 x 12 milking parlour.

Cows I
123 beds with 2 x 2 rows
Good air quality due to roof insulation and horizontal ventilation controlled via blinds
Highest priority for animal welfare
Beds with comfort mattresses
Folding bridge for clean feed tables
Happily tucking in!
Water circuits designed for precise metering of fluid supplements

Cows I – 2 x two-row freestall system

The two-row freestall system, which was newly constructed in 2010, comprises 123 cubicles. The new housing system offers an ideal environment and capacities for testing practice-oriented feeding concepts even more intensely. The cubicle floors are covered with rubber mats, and the comfortable straw/lime mixed bedding is regularly changed.

This area is predominantly reserved for colostrum-producing cows, which benefit substantially from more space for moving around, less stress and the associated improved wellbeing, resulting in a higher feed intake, especially right at the beginning of lactation. This housing system allows two groups of 60 cows each to be directly compared.

The rubber mats on the slatted floor are particularly beneficial for hoof health.

The new housing system is equipped with a so-called feed table bridge, which is folded up before cows cross the feed passage to keep the feed table clean and hygienic at all times as well as to avoid tripping hazards.

Another outstanding feature are water circuits equipped with injection points to allow liquid feed supplements such as Tirsana products to be metered.