dry fertilizer operation with a multi-hopper automated blend system

PROJECT: Frenchman Valley Farmers Coop, Chappell, Nebraska

OVERVIEW

Frenchman Valley Farmers Coop expanded their dry fertilizer operation with a new facility at their Chappell, Nebr., location using a Doyle Autobatch legal-for-trade multi-hopper automated blend system.

WHAT THEY NEEDED

Frenchman Valley needed to upgrade to a larger system to fulfill the intercompany demand within their agronomy division for five other locations. The company had outgrown their old 1,500-ton facility and needed to expand to a more efficient system without the use of scaling trucks. At the same time they wanted to have the same operation as another location to provide flexibility of operation between their sites.

Multi-hopper automated blend system features two swing hoppers, each with a 9-ton capacity.

Five major product bins have a 16-ton capacity each from the new 15,000-ton building.

Reclaim and loadout can be controlled from a loader tablet to maximize the operator’s time.

Kahler system controls 16-ton rotary blender plus conveyors, scales, discharge gates & more.

Loadout without truck scales makes the process more efficient with fewer stops.

Transport info loaded into control room software maximizes capacity and efficiency.

WHAT WE DESIGNED

System to accurately weigh and efficiently blend product
Eliminated need for truck scales and streamlined the prior process bottlenecks
Consistent operational interface across multiple locations
Opportunity for flexible staffing with more internal knowledge and easy product training
Streamlined business management & billing system
Removed need for paper tickets by having tickets sent within software

WHAT THEY HAD TO SAY

Interview with BJ Franken, Operation Manager, Frenchman Valley Farmers Coop, Chappell, NE

Q: How does Kahler Automation help you achieve your business goals?

“It’s really improved our efficiencies and our accuracy in mixing up dry, especially micro blends for VRT. ... We’re achieving high accuracy.”

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

“I believe it is fairly easy to train, easy to run, and it’s a very good programmable system.”

Q: How has productivity improved with your Kahler system?

“Our productivity is probably increased tenfold. When a truck pulls up, we’re ready to go... where our old barn was probably 30-40 minutes to get that prepped, get that loaded, get it mixed, and get it up in the air to get it ready for the truck driver.”

Kahler Automation

KAHLER AUTOMATION DESIGNS CONTROL SYSTEMS FOR DRY MATERIAL HANDLING, LIQUID PRODUCT HANDLING, GRAIN FLOW CONTROL, AND MORE.

If your business handles bulk materials — fertilizers, chemicals, grain, etc. — Kahler can control the process. These automated systems provide the ability to run your facility with ease and accuracy. They control product loadout, receiving and inventory, and tie directly into your accounting/invoicing software, increasing your competitiveness while reducing overhead.

Complete the automation of any facility with Kahler's Streamline, controlling site access, vehicle management, and traffic flow with a single integrated system.