Monitoring the operation of production systems from a computer screen, locating the error, if any, having data that can evaluate the production quantity/efficiency and much more… All these mean time saving, high quality, increased production speed and operating profitability. Which manager wouldn’t want everything in his factory to be this flexible and controllable?
Feed Mill and Machinery Expert
Anderson Feed Technology
Sharing a job between human and machine… This is used as an expression describing automation. The share percentage of the work done between these two elements determines the level of automation. In the simplest terms, automation systems that are manpower-intensive are called semi-automation, and systems that are machine-intensive are called full automation.
So, why automation? Is this really that important? Contrary to the beginning of the industrial revolution, production alone is far from being sufficient in today’s conditions. In competitive conditions where the whole world has become an open market, making production fast, standard, safe and efficient has now become a necessity rather than a preference. Automation is one of the most effective solutions that can provide all these to the manufacturer.
Monitoring the operation of production systems from a computer screen, locating the error, if any, having data that can evaluate the production quantity/efficiency and much more… All these mean time saving, high quality, increased production speed and operating profitability. Which manager wouldn’t want everything in his factory to be this flexible and controllable?
What is the equivalent of automation in feed mills? Wayne Cooper from Anderson Feed Technology is telling us more about this:
If we get down to the basics in a feed mill, what does it actually do?
• Receiving: Bringing in ingredients.
• Grinding: Hammer those ingredients into a particle size for the animals.
• Dosing: Measuring out lbs per batch.
• Mixing: Stir this ration up.
• Pelleting: Reform the particles into a bite size chunk and make it easier to digest.
• Loadout: Drop this batch onto a truck and send it to the farm.
Sounds really simple, doesn’t it? So why is it not totally, completely, 100% automated?
One vision is that the mill could actually be a giant concrete and steel robot. Today’s mills are getting very close to that when completely automated. Think about it: Does the operator of the future come to work to “make feed”? No. The operator comes in to schedule the batches, set up the machinery, feed the micro machines, then sit in the control room and watch the software system operate the robot. Oh wait! Why is there someone sitting in the control room watching the computer make feed? The system will send an alarm if there is a problem. Go do something else! I see this over and over again, so I had to rant for a second. Sorry….
The modern operator comes in to give the robot instructions, maintain the robot, and feed it ingredients. This takes a different skill set than in the past. He/she will probably have in-depth IT skills, have more training, possibly at a tech school or college (Look at Iowa State’s new feed/grain programs. They aren’t the only ones.) And the manual labor is greatly reduced. The robot still can’t unplug the pelleter although it will prevent most plugs. The other KEY RESPONSIBILITY is to maintain the equipment. Strict protocols on preventive maintenance. This equipment needs to be “fixed” before it ever causes a problem. This is no longer a job but a career.
This summer I was in a mill that can be operated not only from a computer, but from your mobile phone at home! And that the mill was built in the 80’s, it just has the proper updates. A new mill can be automated top to bottom. From the ingredient trucker scanning in his load to the delivery driver pulling out his orders and the robot dropping the feed on his truck. It takes some design considerations but there are mills on the drawing board for 80 tons per hour with one operator. It can and will be done.
Does that new mill cost money? Of course it does. But is it less money to operate than paying 5 to 7 people for the next 40 years? It is all about labor vs automation. Which one has caused you the most grief lately? My thinking is that the robot will win most of the time.
About Wayne Cooper
Wayne Cooper operated and supervised feed mills in Iowa, US for 23 years before taking on the job of Director of Feed Technology for the Cherkizovo Group, Russia’s largest meat producer. Those years allowed him to see an international version of the feed industry and the technology on both sides of the Atlantic. He continues to work with feed mill managers to get the most out of their equipment.
