Rubber and foam mattresses are a popular choice for free stall dairy barns because they provide consistent cushioning and a thermal barrier between the cow and the concrete. However, even the best mattress systems still need a modest layer of bedding to maintain hygiene and protect animal health.
While our mattresses greatly reduce the need for deep bedding materials like sand, a small amount of bedding is still essential. Bedding helps absorb moisture, control bacteria, preserve hock health, and maintain overall stall cleanliness. Studies support this need. For example, research from the University of Wisconsin (Cook, 2002) found that cows housed on rubber mattresses without any bedding had a higher incidence of hock lesions and poorer stall hygiene compared to those provided with even a thin layer of sawdust. Similarly, a 2010 study from Cornell University showed that when 1 to 2 pounds of dry bedding per cow per day were used on mattresses — such as sawdust or recycled manure solids (RMS) — the resulting stall cleanliness was comparable to that of deep sand bedding, assuming good management practices.
Field observations also support these findings. In barns where operators have attempted to eliminate bedding entirely, there have been consistent reports of rising somatic cell counts, increased cases of mastitis, cows avoiding stalls, and accelerated wear of the mattresses themselves. These problems are especially pronounced in humid environments where moisture, urine, and manure can sit directly on the surface of the mattress. This creates a breeding ground for bacteria and leads to the deterioration of skin integrity in cows.
Practical and Affordable Cow Lying Comfort
Superior Stall Softness and Cow Comfort
Long-Lasting Tie Stall Comfort
What often gets overlooked is the economic benefit of this minimal bedding approach. Rubber mattress systems allow farmers to cut bedding use dramatically — from about 25 pounds per cow per day with deep bedding systems to just 1 to 2 pounds per day. That reduction can result in substantial savings over time. For example, consider a 100-stall barn. Using deep bedding at 25 pounds per cow per day adds up to more than 900,000 pounds of bedding per year, costing approximately $45,625 annually (at $0.05 per pound). In contrast, using 2 pounds per day with a mattress system only requires about 73,000 pounds of bedding per year, costing around $3,650. That’s an estimated annual savings of nearly $42,000 — or more than $400 per stall.
To get the most out of a rubber mattress system, we recommend using 1 to 2 pounds per cow per day of dry, absorbent bedding, such as kiln-dried sawdust, sand or finely chopped straw. This approach effectively controls moisture, supports udder and skin health, and maintains cow comfort — all while keeping bedding costs significantly lower than traditional systems.
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