New Dry Fertilizer Multi-Bin System with Orbital Mixer & Liquid Loadout Retrofit

PROJECT: AgVantage FS - Mechanicsville, Iowa

OVERVIEW

From the new build to retrofit solution, AgVantage FS has enhanced the speed and efficiency of their dry and liquid loadout operations to meet current and future demand more effectively. The liquid system design features many process improvements that leverage our team’s knowledge, experience, and expertise. From hardware to software, the system has improved inventory accuracy, reducing shrinkage while providing more streamlined business management with expedited invoicing and reporting.

WHAT THEY NEEDED

AgVantage FS needed to update its dry and liquid agronomy center to handle both present demand and the future needs of customers. The company needed to update its inefficient dry fertilizer facility with a cost-effective solution to provide excellent blend quality and increased capacity. AgVantage FS also wanted to expand its offerings with additional dry products to provide a wider range of blend options for customers.

On the liquid side, AgVantage FS needed faster loadout and accuracy to match the pace of their applicators. The company needed a high-quality custom solution to maximize the efficiency of existing building design systems and avoid the need for a complete overhaul. Several aspects of the operation, including the repack process and billing, were inefficient and time-consuming. AgVantage FS needed to clearly understand inventory to help improve its business management and integration with Agvance.

The facility features Kahler Automation in the new dry fertilizer building along with a retrofit upgrade to the liquid fertilizer and chemical building.

The control room with Plant Supervisor PSX® software allows staff to accurately fulfill product dispensing for the various blend orders. Wait time is minimal as trucks can be loaded twice as fast as the prior system.

The wall-mounted touchscreen provides quick and easy control.

The Kahler system controls a multi-bin system that features scales, discharge gates, conveyors, and an 8-ton orbital mixer. The system has six main bins, one swing, and three micro bins.

The system features a receiving panel with handheld remote for easy in-bin product position control. Product is received by truck and is three times faster than the prior system.

The redesigned liquid system improves product throughput and productivity. Trucks can now be filled in under 10 minutes versus an hour with the prior automation system.

A three-inch mass flow meter replaced a magnetic meter to allow for higher flow.

Legal-for-trade mass flow meters that are accurate to 1/10th of a pound and have a capacity of 1,000 lbs of water per minute.

Eight mini-bulks are plumbed to a 130-gallon weigh tank with flexibility to be switched out depending on the season.

The repack station is now positioned by the bay to ensure mini-bulks stay on the truck for a more efficient and streamlined loadout.

Using Plant Supervisor PSX software within the entire site makes it easy for staff to learn and operate within different areas.

WHAT WE DESIGNED

The initial project objective was construction of a new dry fertilizer building, with subsequent retrofit upgrades to the liquid fertilizer and crop protection building. We evaluated the facility’s overall cost of ownership and performance; we took into account both the liquid and dry components to provide seamless integration. The state-of-the-art dry facility supplies five different outlets in their region. The system is set up for 11 products plus swing products for precise blending. The motor control center with terminal nest offers quick and easy setup for onsite service.

The liquid system features legal-for-trade mass flow meters for each chemical, so that everything can be run simultaneously to speed up loadout. Controls and software are common throughout this location, allowing for flexible staffing with more internal knowledge and easy product training. Electronic order integration provides a paperless process, eliminating manual entry errors for fast and accurate accounting.

SPECS AT A GLANCE

GENERAL

Business Name & Location: AgVantage FS in Mechanicsville, Iowa
Type of Business: Retail
Products Offered: Dry Fertilizer, Liquid Fertilizer, Crop Protection Chemicals
Total Acres: 2.4
Total Square Feet: 104,000
Receive Product Via: Truck

DRY FERTILIZER

Dry Fertilizer Storage Capacity: 8,330 tons
Number of Storage Bins: 6
Total Tons per Year: 12,600
Total Tons per Day: 250 to 300
Tons per Hour: 65
Receiving Capacity: 200 TPH
Loadout Capacity: 100 to 250 TPH
Blending Type: Orbital
Number of Materials in Typical Blend: 2-4
Micronutrients: 3
Impregnation: Yes, 2
Batch Sizes Offered: Any combination
Number of Trucks per Hour: 5
Truck Scale: Not required
Number of Operators Required: 1
Control System: Kahler Automation

LIQUID FERTILIZER & CROP PROTECTION

Liquid Fertilizer Storage Capacity: 120,000 gallons in 5 tanks
Type of Liquids Stored: 28% and Ammonium Thiosulfate (ATS)
Tonnage per Hour: 100
Number of Trucks per Hour: 6
Bulk Chemical Storage Capacity: 8 tanks, 8 totes for over 24,000 gallons
Loadout Capacity: Up to 400 GPM
Number of Operators Required: 1
Control System: Kahler Automation

WHAT THEY HAD TO SAY

Brad Newhard, Dry Shed Operator, AgVantage FS:

“We have spot-on loading, our weights come out right, our inventory comes out right. We can blend a lot more products. We only had two products before and now we have seven. Productivity is better than I ever expected.”

Angie Dusanek, Admin, AgVantage FS:

“Most of my job is billing for the chemical, seed, and fertilizer. With the old system … there was a lot of manual adding which ups the risk of counting errors and things like that. The new Kahler system … has made that quicker. The nice thing is it comes in automatically.”