From swampland to model farm

A publicity-shy Auckland businessman has created a model dairy farm from unpromising beginnings. KATE GARDEN reports.

Bruce Pulman wants Marphona Farms to be the best, number one, a model for the dairy industry.

To add to the challenge, the Papakura businessman better known as an earthmoving contractor and district benefactor chose Mangatawhiri swampland to turn into a farm rated one of the highest for quality in New Zealand.

Since 1983, Mr Pulman and his wife, Jessie, have bought more than 800ha, leased 400ha and combined their knowledge of dairy farming with their earthmoving machinery to create a highly functional, ideal farm.

The result is a 1254ha property with precisely surveyed paddocks of matching size running 3000 cattle and producing up to 27,000 litres of milk a day.

It has two, state-of-the-art, 50-bale rotary dairies milking 400 cows an hour, is close to gaining organic certification and, despite little promotion, is a tourist attraction.

Quality-control checks and procedures have enabled the farm to gain high ratings. Marphona Farms has a category two Occupational Safety and Health (OSH) rating, which farm manager Kevin Blake believes is the highest level of safety assurance for any dairy farm in the country.

Safety equipment such as gloves and eye protectors are worn by the 12 workers on the farm. Guards on machinery protect clothing and hands from being caught in blades or shafts. Maintenance of machinery, and auditing of quality standards are done regularly.

The farm has recently achieved ISO 9002 accreditation - a world-recognised quality-assurance certification for any industry. An example of the farm's rigorous control checks is the recording system for its calves.

The farm has two herds supplying milk year-round directly to domestic market dairy product company New Zealand Dairy Foods. One herd has 1200 head with 900 in milk at any one time, and the other has 800 head.

To ensure an even milk production, 300 cows calve every 12 weeks, or four times a year.

The calves are housed inside until they reach target weights, and afterwards are brought inside in poor weather. They are weighed six-weekly from birth until two years, with their records kept for reference. If a calf is underweight at any point in the two years, its health and feeding programme is reassessed.

The farm's focus on quality sets it apart. It is also the reason northern China has sought Mr Pulman's help.

On a visit to China in 1998, National MP for Hunua Warren Kyd invited the then governor of the province, Shan Rong Fan to visit New Zealand to study the dairy industry.

Mr Fan wanted to improve the standard of milk produced by northern Chinese farmers, establish a quality management system and use New Zealand technology.

Farmers in northern China milk on average three cows by hand each day. The milk is often unfiltered and left unrefrigerated before being sold.

Mr Pulman's son Philip, the project manager, said Mr Fan looked at New Zealand farms and identified Marphona Farms as "the way to go."

"Our farm is set up with a system where we have a manager and staff wanting to achieve goals similar to what they wish to achieve."

The Pulmans and Mr Blake were invited to northern China to advise the Government on improvements to the dairy industry. They are still investigating the project.

Philip Pulman said harsh weather and short growing seasons were some of the difficulties facing the Chinese.

"We are planning to build barns to house around 600 cows each, and to develop the land to produce large harvests that will enable feed to be stored to last for the seven to eight months of icy, frosty winter weather."

Mr Pulman sen is hoping to export milking machines and New Zealand processing plants to enable China to improve its milk quality.

Philip Pulman said his father appreciated people who think laterally and differently about the dairy industry.

"He doesn't see any future in going down the traditional farming path," he said, adding that his father had confidence in the New Zealand industry but believed a change of strategies and attitudes had to occur soon.

Marphona Farms is building a $3.5 million, 80-bale rotary dairy catering for tourists with a glassed-in viewing platform, offering information in several languages and providing a cafe, souvenir shop, seminar and conference facilities.

On the tourist route from Auckland to Rotorua, it already hosts about two busloads of mostly Asian tourists each week. The farm has not advertised but is known among travel agents who respond to requests from tourists interested in farming.

Another plan expected to happen over the next 10 years is the establishment of an education centre for farmers and students.

Philip Pulman said a lot of graduates of technical institutions gained a solid theory base but had very little hands-on experience. "We would like to show them what we do, and explain to them why we do it."

It had always been Bruce Pulman's aim for the farm to be used as a model for the industry.

"We've got a tourism cowshed, an education centre and the China project all in the planning stages. When it happens, it's going to be crazy around here for a while."