Bulk Weigh Grain Handling Automation

PROJECT: Farmers Cooperative, Dorchester, Nebraska

OVERVIEW

Farmers Cooperative automated their bulk weigh grain handling on the rail loadout system at their 7 million bushel grain facility in Dorchester, NE.

WHAT THEY NEEDED

Their prior system had a track scale that weighed every car in and out, generating a ticket for each one, and everything required manual data entry. Farmers Cooperative wanted to streamline their grain loadout and billing process, and at the same time take full control to precisely blend grain.

The system controls bin percentage gates to allow for accurate blending.

The system monitors high & mid-level sensors in the bulk weigher w/70,000 bu./hr capacity.

A couple of numerous bearing and rub block sensors in the hazard monitoring system.

A touchscreen panel in the control room allows for easy monitoring and control.

Operators have full control, with everything a click away for complete focus during loadout.

One car of many from a 110-car unit train that gets quickly loaded.

WHAT WE DESIGNED

Grain blending control on eight bin percentage gates and three conveyors that fill bulk weigher
Accurate loadout with bulk weigher tank level monitoring and garner control
Hazard monitoring of belts, drag conveyors, and legs using combination of bearing temp sensors, rub block sensors, and speed switches with systematic shutdown processes
Streamlined billing for easy processing after loadout completes
On-site startup service for testing and training on system operation.

WHAT THEY HAD TO SAY

Interview with Larry Chapman, Project Manager, Farmers Cooperative, Dorchester, NE

Q: What was the reason you got Kahler Automation involved in this project?

“We have used Kahler on a lot of our agronomy systems and their price point was a lot better than on some of the other ones. We have two other grain loading facilities that run Kahler and everybody seems to like it.”

Q: How has productivity improved with your Kahler system?

“Productivity here has improved a lot. It used to take us 14 or so hours to load a train the way we did it before; now we can do it in ... about 8 to 8 1/2 hours, with switch time you're running about 10 1/2. We’ve cut down probably about 6 people.”

Q: How does Kahler Automation training and support help your team?

“They're really good. If you’ve got a problem you call them. They can usually just remote in; you can get on the phone with them at the same time and fix any problems you have. They are really Johnny-on-the-Spot.”