Bovine respiratory disease (BRD) continues to be one of the most costly and challenging health issues for young dairy calves. After weaning, pneumonia becomes the leading cause of death in dairy replacements, creating significant setbacks in health, welfare, and long-term productivity.
A new research project, funded through a three-year, $1 million U.S. National Science Foundation grant, aims to give dairy farmers a new tool for earlier detection. Researchers from Penn State, the University of Kentucky, and the University of Delaware are developing an artificial intelligence (AI)–powered monitoring system designed to spot subtle signs of pneumonia before calves show visible symptoms.
Early Detection Could Change How Dairy Farms Manage Calf Health
Melissa Cantor, assistant professor of precision dairy science at Penn State, is helping lead the development of the system—called CalfHealth.
“Early detection saves calves, cuts antibiotic use, and improves long-term performance,” she explained. “Our goal is to build a tool that is accurate, affordable, and practical for real dairy farms.”
The CalfHealth system uses a combination of precision technologies already familiar on many dairies, paired with new AI methods that analyze changes in calf behavior, feeding patterns, and breathing.
How the CalfHealth System Works
The system gathers information from several low-cost sources:
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Wearable sensors on calves track activity, steps, and resting time.
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Robotic milk feeders monitor feeding patterns and intake changes.
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A Wi-Fi-based tool detects changes in breathing without needing physical contact.
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Deep-learning AI analyzes all data streams and flags patterns linked to early BRD.
Because every dairy operates differently, the system is being designed to adapt to a variety of barn layouts, feeding systems, and management styles without requiring complicated setup.
Improving Trust Through a Farmer-Friendly Chatbot
One of the project’s unique components is an explainable AI chatbot designed specifically for dairy producers. The chatbot will:
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clarify why the system flagged a calf,
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answer health and behavior questions in simple language, and
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allow farmers to run “what-if” scenarios, such as “What if feeding drops but breathing stays normal?”
The goal is to help farmers understand the system’s decisions so they feel confident acting on its recommendations.
On-Farm Testing and Adoption Research
The project will include real-world testing on multiple dairy farms to measure:
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accuracy of early detection,
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impact on calf health and survival,
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changes in antibiotic use,
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economic benefits for producers.
Researchers will also study how dairy farmers build trust in new technologies and what factors encourage or discourage adoption.
Workshops, demonstrations, and outreach programs will share findings with producers, veterinarians, and industry partners.
Supporting Healthier Calves and More Efficient Dairies
If successful, CalfHealth could give dairy producers a reliable way to catch BRD earlier—reducing treatment costs, improving welfare, and supporting stronger growth in the heifer raising program.
With pneumonia remaining a major barrier to raising healthy, productive replacements, tools like this may soon become an important part of future dairy management.
