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From farm roots to technical leadership
Seamus’s story starts where many good agri stories do—on a farm. After studying agriculture at UCD (late 70s/early 80s) and serving as an agricultural advisor with Bailieborough Co-op, he joined Volac in 1986, covering Munster. By 1991, Durapak was founded with a focus on crop packaging—bale wrap and everything that kept the silage system humming.
Very quickly, farmer needs pulled the business into animal comfort: by 1992, EVA mats were part of the range. The thinking was seasonal balance—crop packaging kept the team flat out from April to September, then winter housing products (mats, silicone tubing and more) carried the momentum through the colder months.
“At shows, people kept asking—you’ve mats for cows, anything for beef? That’s what pushed us to look seriously at slatted solutions.”
Why slatted rubber took off in Ireland
Ireland’s shed profile is unique—lots of smaller sheds, limited access to straw, and a climate that makes rubber coverage incredibly practical. While some continental systems leaned heavily on straw, Ireland’s reality made rubber on slats an efficiency and welfare win—particularly as stocking rates and finishing goals evolved.
The early trials taught hard lessons: EVA expanded on slats and couldn’t stay bonded. The pivot to robust rubber wasn’t just a material change; it was the beginning of a design philosophy that led to Durapak’s signature system.
The Durapak advantage: three strips, two wedges
Durapak’s now-famous three-strip rubber with two parallel wedge rows aims at one core promise: once installed, it stays installed.
Think of it like house foundations. Two parallel anchor lines (left and right) provide far better long-term stability than a single central line. The result?
- Harder for animals to lift
- Allows a softer, warmer, more comfortable top without compromising hold
- Lower maintenance stress for the farmer over the life of the shed
Evidence that matters: the Grange trials (and a later review)
Independent research matters—especially when you’re investing across an entire shed. At Teagasc/Grange, a large comparative trial (first presented publicly in 2008) ran 360 cattle across bare concrete and several slatted rubber options.
As discussed in this episode, results showed meaningful performance differences:
- Carcass weight on concrete: ~372 kg
- Durapak: ~386 kg
- Two other mats: ~381 kg and ~375 kg
Back then, superimposing prices translated to around €50 extra per head for Durapak. In today’s prices (2025), €140 per head is a realistic extrapolation from the same performance uplift—plus the 2–2.5 season payback often referenced from the original numbers.
And that’s just direct performance. As Seamus notes, there are additional wins that don’t always make the spreadsheet:
- Fewer slips and injuries on hard slats
- Lower vet bills
- The option to finish earlier if needed
A later review led by Dr. Bernard Earley re-examined the literature and ran a fresh comparative look (work conducted over multiple years, presented in 2021), again showing similar directional benefits for slatted rubber vs. concrete.
“When the research is rigorous and replicated, farmers can make confident, numbers-based decisions.”
Note: Figures and timelines referenced above are as discussed in this episode.
Going international: a major project in Poland
Since joining the Creva International family (August 2023), Durapak has been pushing its solutions further afield. Seamus was instrumental in helping secure a significant Polish install—a market where straw use is still common, but where larger units and a rising share of slatted housing (even if just 10–20%) make a strong case for rubber.
The three-strip/two-wedge story travels well: secure anchoring, comfort gains, tangible performance. And as Seamus puts it, the sky’s the limit when you bring Irish-born practicality to international markets.
What this means for your yard (the quick math)
- Performance uplift: Historically ~+14 kg carcass vs. concrete in trials
- € per head: Then ~€50; today ~€140 (episode extrapolation)
- Payback: Often 2–2.5 winters based on trial-time economics
- Hidden wins: Reduced lameness & slips, lower vet costs, earlier finishing options
Every yard is different. But when the shed profile, stock class, and finishing goals line up, the Durapak system has consistently proven itself on comfort, performance, and durability.
Legacy, transition, and what’s next
This episode is also about legacy. Durapak’s story spans friendly competition, caravans at shows, cups of tea, and a relentless focus on farmer outcomes. Now, with Creva’s backing, the brand is scaling up: new branding, broader product set, and a team blending experience and fresh energy—with leaders like Jamie and John Joe pushing “Long-life solutions for long-life cows” forward.
“It’s been a pleasure to be competitors—and an even bigger pleasure to build together.”