Rethinking slatted floors: Less ammonia, drier floors, and healthier hooves

Expert knowledge

If you want to future-proof your barn and invest in sustainable dairy farming, you should consider options for reducing emissions. At present, cattle farmers are only obliged to implement emission-reducing measures in or at their barns if their herds exceed a certain size or if they are located in particularly ecologically sensitive areas. However, their implementation is already being promoted at government level through investment promotion programs – these vary from region to region. Eligible measures include emission-reducing rubber flooring for walking areas. For perforated floors in particular, workable systems have been limited so far. This is exactly where espaFLEX comes in.

State of the art to reduce ammonia emissions on perforated floors

Slit-reduced slatted floors and specialized rubber flooring

To reduce emissions, conventional slatted floors are replaced by slit-reduced slatted floors or equipped with specialized rubber floorings. Typically, these floorings feature a concave design with a slope toward each slit, allowing liquids to drain quickly. Manure is regularly removed by a manure removal system. According to KTBL* (2024), this can reduce ammonia emissions by up to 38%.

The rubber mats currently available on the market generally do not fit all types of slatted floors, as slat widths vary by manufacturer and model. Existing concave slatted floor coverings are often difficult for cleaning robots to clean thoroughly because of the quick changes in slope. In addition, there are often “valleys” where a slit is not possible, causing puddles to form. Consequently, these mats offer only limited flexibility for reducing slits, since the slit pattern cannot be adjusted freely.

In practice, they have proven effective for liquid drainage and sure-footedness – making them a good option for young cattle housing. However, for the walking alleys in a dairy barn, the disadvantages mentioned above (puddling, cleaning challenges, limited flexibility) can be an issue.

^{* KTBL, 2024: Förderfähige Techniken zur Emissionsminderung in Stallbauten}

Sealing flaps

Some manufacturers offer slat inserts with sealing flaps to minimize gas exchange from the slurry pit. However, in general, the reliability of these flaps decreases over time (clogging, wear, etc.).

The idea: One mat for everything

Based on these experiences, KRAIBURG has developed a novel emission-reducing rubber covering for slatted floors: espaFLEX with integrated slope and easy-to-reduce ratio of slits. Thanks to its special design with a 3% slope on both sides from the center to the edges, this mat fits any slatted-floor geometry while retaining full functionality. Its unique slope structure quickly and reliably drains off liquids, assuring drainage regardless of the position, number and size of slits. Rapid urine drainage lowers ammonia release and keeps hooves drier.

To further reduce emissions (gas exchange with the slurry pit), the slit ratio on espaFLEX can be easily decreased (for robot scrapers) or set up with only small drainage openings (for robot collectors). Cleaning robots achieve good cleaning results thanks to the gentle “wave” in the direction of the walking alley.

Hoof-friendly and slip-resistant

In addition to reducing emissions, espaFLEX also provides sure-footedness and protects hoof health. Its ideally balanced deformability offers cow-friendly walking comfort and helps prevent mechanical-traumatic hoof diseases. The proven surface texture is easy to clean and supports slip resistance. Drier walking areas also mean drier hooves, positively impacting hoof health (fewer infectious hoof diseases).

Awarded the DLG "Innovation Award 2024" in silver

espaFLEX was awarded the DLG “Innovation Award EuroTier 2024” in silver. The DLG novelty prize „Innovation Award EuroTier“ is one of the leading awards within the international agricultural industry.

Advantages at a glance:

For farmers:

Ideal for every slat geometry
Easy to retrofit
Variable slit reduction possible without any problems (also renovation only with drainage conceivable)

For the environment:

Liquids can drain away easily
Fewer emissions from the slurry pit
Preliminary tests suggest a high ammonia reduction potential.
Detailed emission measurements are being planned.

For cows:

Robot scrapers achieve good cleaning results
Proven surface with square imprinting for high slip resistance
Further enhanced softness supports hoof health

Ratio of slits – a comparison

Ratio of slits in regular slatted floor element: approx. 20%
Ratio of slits in standard slatted flooring: approx. 12 - 15%
Ratio of slits in this example with espaFLEX: approx. 8%

Outlook & vision:

"The system has almost no limitations"

With espaFLEX, you can renovate slatted floors with a minimal slit ratio – even down to just drainage openings at the mat edges. If espaFLEX is fitted only with drainage openings at the mat edges, it’s also conceivable that the urine is drained into a “urine pit” below while manure is collected by a robot collector.

Conceivable: Reducing the slits to a minimum

In the future, this also allows for the possibility of zoning into different barn areas with different ratios of slits (or even none at all) depending on frequency of use or the volume of feces/urine. For instance, a lot of feces/urine accumulates behind the free stalls, behind the standing area at the feeding table or in the waiting areas around the milking robot. In other parts of the barn, however, there is little feces/urine, where it is advisable to minimize the slit ratio.

Conclusion

espaFLEX is the logical next step in rubber coverings for perforated floors in cattle housing. Thanks to its sophisticated construction, integrated slope and flexible slit coverage, this system harmonizes emission reduction, hoof health and walking comfort. Moreover, espaFLEX opens the door to entirely new systems in the future.

This is cow comfort and emission protection hand in hand for both new construction and renovation.

Download PDF file:
KRAIBURG Guidance Rethinking slatted floors PDF

More information about the product:
espaFLEX visit product page

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