"Automation without borders: the first in Ukraine SCADA from Grain Capital, which works without an operator"

"Turyiskyi Feed Mill", which is part of the Risters group (APG "Pan Kurchak") became a pioneer in Ukraine, having successfully implemented a feed shipment automation system. Thanks to the SCADA system developed by Grain Capital, the plant achieved unprecedented accuracy and efficiency, minimizing the human factor. Read more about this innovative project in our article."

Modern requirements for grain processing enterprises prioritize speed, accuracy and automation of production processes, which allows minimizing the number of personnel involved in performing standard work. Shipment of finished products is one of the key business processes, because any delays or errors can lead to serious financial losses and pose a threat to the health of livestock.

Grain Capital, known for its experience in engineering and automation, successfully solves these problems thanks to the methodology: first - optimization of business processes, and only then - development and implementation of technical solutions.

Problems of a feed mill for modernization

The Turin feed mill faced a number of problems at the feed loading unit for motor transport. One of the main problems was the use of manual labor and manual control, which increased the risk of errors and slowed down the process. Low productivity and dependence on the qualifications of all participants in the process and the quality of communications between them became a serious challenge at the enterprise.

The customer representative noted: “Manual processes were the main obstacle to improving the efficiency of our production. This led to high labor costs and the risk of human error.”

Grain Capital's solution included both the modernization of the feed loading unit onto motor transport, and the updating and automation of business processes.

The following works were performed as part of the feed loading unit modernization project:

• engineering of the modernization of process lines, storage capacities and compressed air system;
• engineering of an integrated system for performing business processes and industrial automation;
• manufacturing and supply of transport and gravity equipment, air dryer;
• dismantling of existing equipment and structures;
• installation of new metal structures, process equipment, truck scales;
• organization of power supply systems and integrated automation of internal and external expeditions;
• development of software for an industrial controller, weighing terminal, message server;
• integration with the customer's internal systems;
• bench testing of the system;
• commissioning and comprehensive testing.

The key element of the process line modernization was a mobile chain conveyor, developed specifically for loading a feed truck on a static truck scale. This conveyor, equipped with loading sleeves with built-in aspiration, significantly increased the accuracy and efficiency of the process.

Analysis and automation of business processes for loading compound feed onto feed trucks

Having received the initial request from the customer, Grain Capital specialists identified the key need to automate the process of loading finished products (compound feed) onto feed trucks.

Although the request sounded like a big challenge: “The goal of the project is maximum automation of the loading business process. Ideally, only one participant should be physically involved in the process, which is indispensable: the driver. The functions of the SCADA operator, weigher, checking the availability of the loading document - all must be performed by the system.”

The project team, headed by the First Deputy Director for Technical Issues Radchenko M.D., together with Grain Capital, began a detailed study of the business requirements.

The main problems were in the manual management of processes, which led to:

• loss of time and errors in the loading business process due to the human factor;
• increased risks of errors;
• significant labor costs;
• the need to attract qualified workers.

To solve certain problems, an optimal sequence of business processes was established and transferred to a sequence diagram. The document was developed so that all stakeholders from top management to technical personnel clearly understood their role, stages of inclusion, actions and options for solving unforeseen situations.

Based on the diagram, a technical task was developed, which included:

• description of the desired standard shipment process;
• possible deviations from the process;
• system responses to each of the scenarios.

The result was a comprehensive system combining several key components: an accounting system, a weighing controller, an information message server, SCADA "SMART-SDAU".

The updated business process, taking into account the modernization of equipment and automation, includes the following stages:

• Task creation: based on delivery plans, unloading tasks are created.
• RFID tag reading: when a feed truck arrives, the system reads the vehicle tag, checks for an active task for a specific vehicle and displays an invitation to load.
• Automated process: the driver performs minimal actions (position and lower the sleeve, press the "Start" button), the system performs the rest of the process independently: it plots a route, monitors the weight of the product and issues instructions on the board - that is, it automatically performs unloading tasks.
• Monitoring and safety: the system displays up-to-date data on the task status and stops the process in the event of an emergency.

During the modernization work, some unforeseen situations arose, but thanks to the plant's readiness to adapt, the project was successfully implemented.

The customer received a system that meets its current needs and provides for the agreed requirements for an optimal business process:

• operator participation - only in emergency situations, which allows minimizing labor costs;
• guaranteed supplies to poultry and livestock enterprises of both the customer and its clients: there will be no errors in the recipe, and, accordingly, no negative consequences for the livestock;
• a clearly implemented "planning-implementation-analysis" chain: the enterprise's work with an expected and controlled result.

A representative of the plant noted: "Thanks to automation, we have significantly increased work efficiency, reduced the influence of the human factor and improved the accuracy of order fulfillment."

The project to modernize the feed shipment unit at the Turiysky feed mill has become another example of successful cooperation between Grain Capital and the customer. The work performed not only increased production efficiency, but also allowed the plant to provide guaranteed deliveries of products to its customers without errors and failures. This is especially important for poultry and livestock enterprises, where the accuracy of feed recipes has a direct impact on the health of the livestock. 

Want to achieve the same results? We offer individual solutions for the automation of your production. For more information, please contact our commercial department by phone: +38 (048) 786-83-00; +38 (067) 558-58-37; +38 (063) 156-68-22 or by e-mail: info@zeo.ua