--- title: "Dairy Farm Sensor-Activated Spray System — Donglin Controls" description: "A commercial dairy needed to move beyond row-level spraying. We engineered a stall-level control system that detects cow presence and activates only the corresponding spray position." canonical: https://efmc-automation.com/en/cases/precision-spray-cooling-dairy-retrofit language: en --- ![Sensor-activated spray-cooling retrofit in a commercial dairy barn](/api/media/file/hero-dairy-barn.webp) Agriculture & Livestock # Dairy Farm Sensor-Activated Spray System A commercial dairy needed to move beyond row-level spraying. We engineered a stall-level control system that detects cow presence and activates only the corresponding spray position. IndustryAgriculture & Livestock 01 Client challenge ## The system could deliver water—but not according to actual cow occupancy. “ Detect whether a cow is present at each position, and activate only the nozzle serving that occupied position. **01** ### Empty-position spraying Every nozzle on the line operated, even when positions were unoccupied. **02** ### Coarse control A single valve controlled an entire row—or, in some areas, a complete barn line. **03** ### Installation and maintenance burden Long cable runs and secondary field wiring slowed installation and troubleshooting. 02 The control transformation ## From pipe-level operation to cow-position-level control. ![Engineering comparison of row-level spraying and position-level precision control](/api/media/file/control-transformation.webp) 03 Engineered system ## One coordinated architecture—from presence detection to remote operations. The requirement could not be solved by adding a sensor alone. Sensing, field connectivity, PLC decision logic, individual valve actuation and operator visibility had to operate as one control loop. ![Layered architecture of the sensor-activated precision spray-cooling system](/api/media/file/system-architecture.webp) Presence Detection → Field Signal → PLC Decision → Individual Valve Actuation → Operational Feedback 04 Purpose-built hardware and software ## Four custom elements designed around the barn—not adapted from a generic control package. ![Purpose-built sensing enclosure](/api/media/file/sensing-enclosure-640x480.webp) 01 / Sensing ### Purpose-Built Sensing Enclosure Evaluates cow presence at the corresponding spray position and sends the field signal to the control system. ![Plug-and-play T-cable harness](/api/media/file/t-cable-harness-640x480.webp) 02 / Connectivity ### Plug-and-Play T-Cable Harness Standardized connections eliminate unnecessary secondary wiring and simplify installation, replacement and expansion. ![Dedicated PLC control panel](/api/media/file/plc-control-panel-640x480.webp) 03 / Control ### Dedicated PLC Control Applies presence, temperature, timing and zoning logic before commanding the corresponding solenoid valve. ![Mobile equipment status screen](/api/media/file/mobile-operations-app-640x480.webp) 04 / Operations ### Mobile Operations App Provides equipment status, operating visibility, parameter review and faster localization of abnormal device states. 05 Delivery approach ## Survey first. Configure for the actual barn. Retrofit by zone. 01 **Site Survey** Map water, power, cable routes and existing controls.**›** 02 **Control Zoning** Define positions, sensors, valves and spray points.**›** 03 **Configuration** Prepare enclosures, harnesses and panels for the barn.**›** 04 **Installation** Retrofit by zone to reduce operational disruption.**›** 05 **Commissioning** Verify detection, control logic, valve response and timing.**›** 06 **Handover** Configure mobile operations and train the dairy team. 06 Before and after ## A measurable change in how the system is controlled and maintained. Control area Before retrofit After retrofit Presence detection No position-level detection Presence evaluated at each spray position Spray control Entire row or barn line Individual occupied positions Field connection Secondary wiring required Plug-and-play T-cable harness Control logic Coarse line-level operation PLC-based temperature, timing and zoning logic System visibility On-site inspection Mobile equipment-status visibility Troubleshooting Broad manual search Faster localization by zone and device 07 Value delivered ## Precision at the spray position. Simplicity in the field. Visibility for operations. ### More Targeted Cooling Spray activation follows actual occupancy instead of opening every nozzle on the line. ### Cleaner Installation Purpose-built, plug-and-play connections reduce field wiring and make replacement easier. ### More Visible Operations PLC control and the mobile interface make status, parameters and abnormal conditions easier to manage. Project perspective ## The retrofit redefined the smallest controllable unit of the cooling system. Control moved from the pipe level to the cow-position level—supported by purpose-built sensing, connectivity, automation and mobile operations. > The goal is not to make every nozzle operate. It is to make the right nozzle operate at the right position. ## Products used in this project [![Siemens S7-1200 PLC Control Cabinet (1)](/api/media/file/01-7-640x480.webp)](/en/products/siemens-s7-1200-plc-control-cabinet) ### [Siemens S7-1200 PLC Control Cabinet](/en/products/siemens-s7-1200-plc-control-cabinet) Custom-built control cabinets around the Siemens S7-1200 platform, wired, programmed and factory-tested to your process specification. [Request a Quote →](/en/products/siemens-s7-1200-plc-control-cabinet) [![Instrument Enclosure / Operator & Valve Control Box (1)](/api/media/file/01-2-640x480.webp)](/en/products/instrument-enclosure-operator-valve-control-box) ### [Instrument Enclosure / Operator & Valve Control Box](/en/products/instrument-enclosure-operator-valve-control-box) Field enclosures for instruments, operator controls and solenoid valves, sized and drilled to your layout. [Request a Quote →](/en/products/instrument-enclosure-operator-valve-control-box)