Sterilising cow teats before milking is more than a hygiene protocol, it’s essential for safeguarding animal welfare and ensuring the safety of dairy products. Clean teats help prevent painful infections that can compromise a cow’s health and reduce milk yield. For consumers, this translates into milk that is safer, cleaner and free from contaminants.
Yet automating this process has proven difficult. Cows vary in size, shape and behaviour, making it hard for machines to reliably identify and clean teats without causing stress or discomfort. The challenge lies in developing a system that can adapt to biological variability while maintaining accurate teat detection and consistent, low-stress contact.
CR Solutions, an automation specialist based in Rochdale, saw an opportunity to address this. With a strong track record in sectors like pharmaceuticals and aerospace, they brought engineering expertise to a new frontier –the dairy industry. Their partnership with the University of Huddersfield helped establish a dedicated mechanical design department and in-house manufacturing capability, laying the foundation for innovation.
With support from the Advanced Machinery and Productivity Institute (AMPI), CR Solutions launched SaniCleanse – a robotic system designed to automate teat sterilisation using advanced robotics and artificial intelligence.
The team developed an automation system equipped with a custom-designed end effector, mounted on a robotic arm. This tool needed to be both precise and consistent, capable of navigating the complex geometry of a cow’s udder without causing discomfort or injury.
To achieve this, CR Solutions integrated deep learning algorithms trained on thousands of images to recognise teat positions in real time. Unlike traditional machine vision systems that rely on fixed rules, deep learning enables the robot to adapt to different cows by learning patterns and variations in shape, size and orientation.
A multi-camera array builds a 3D model of the udder, guiding the end effector with sub-centimetre accuracy. The cleaning mechanism uses a low-pressure, rotating spray system that ensures thorough sterilisation while minimising water and chemical use.
The system’s modular design allows high-wear components to be easily accessed and replaced, reducing downtime and simplifying maintenance for farmers.
The results are tangible. CR Solutions secured an initial order for 10 systems worth £1.3 million, with interest in 20 more – its largest fulfilment to date. The company has also expanded into new sectors, winning a contract in pharmaceutical automation thanks to its enhanced capabilities in AI and machine vision.
AMPI’s support was instrumental, not only in funding the project but in enabling collaboration across disciplines. CR Solutions worked with academic researchers and fellow AMPI partners to refine mechanical designs, optimise AI models and prototype the system using advanced manufacturing tools.
The project created new talent development pathways through AMPI, enabling CR Solutions to recruit three apprentices: one completed a master’s degree in mechanical design focused on the end effector; another now works full-time in CAD/CAM after machining key components; and the third trained as an electrical apprentice and is now employed as a wiring technician.
These apprentices gained hands-on experience in an innovative environment, bridging the gap between education and industry and contributing directly to the UK’s advanced manufacturing capability.
The project has enabled CR Solutions to invest in equipment and tools previously only accessible in academic settings. Their work in AI and camera systems has broadened their skillset and customer base, positioning them for future growth.
“As far as I’m concerned, it’s absolutely vital that an institution like AMPI exists. It brings the focus to innovative technology. If we want the UK to be strong, levelling up manufacturing in the North-West is crucial. This needs to happen to give people job security – not just high-quality jobs; careers with meaningful salaries and a good standard of living.”
— Steve Bennett, Managing Director, CR Solutions
