With the average U.S. dairy herd sizes more than doubling in the last two decades, producers nationwide face a critical question: When does herd growth demand parlor expansion?

The newest addition to Washington State University’s (WSU) Knott Dairy Center (KDC) is a flexible, compost-bedded pack barn that houses developmental and pregnant heifers, dry cows and has space for a pen of research animals. Construction began in July 2024 and was completed in June 2025.

A well-conceived and coordinated plan is essential for a successful expansion that achieves the dairy family's objectives. Here are key areas to address and implement.

Suz Brouwer captions every one of her social media posts with #dreambig, and with good reason – her dream of owning and operating her own dairy farm has come true after 20 years of hard work.

In this article, I’d like to share some common concerns I see arise and offer practical solutions. These are things you should consider during the design process whether you’re investing in a new facility or seeking to enhance an existing one.

Are you considering expanding your milking parlor? If so, you probably know how daunting of a task it can be. However, with proper planning and the right resources, expanding your parlor can increase efficiency and productivity for your operation. 

The underlying factor when trying to make big decisions on whether to build a freestall barn, heifer shed, new parlor or that new robot barn is what it will be worth once it is erected and operational.