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The sole purpose of Tri-State LLC, located in Fairmount, ND, is to supply either raw or blended fertilizer for other retailers. For that reason, it has to be efficient. Agronomy and operations manager Brad VanOverbeke says, “We want to accurately track all product going out of the building, monitor inventory, and speed up the process while virtually eliminating human error.”
To meet these goals, Tri-State broke ground on a 38,000-ton-capacity plant in March 2004 and completed construction by October 1. With existing rail service, it can now unload 800 tons/hr. supplied by as many as 100 train cars. Receiving is automated with Kahler Automation's KA-1510AG rail receive system. Touted as a hybrid model with a gate control, this unit monitors all functions of the receiving equipment. As the system is unloading railcars, the gate opens and closes to maintain maximum rate of flow, reducing off-loading time while minimizing the chance that the fertilizer will jam up.
The drag conveyor, bucket elevator leg and transfer conveyor are all continuously monitored for speed, and the bucket elevator is monitored for amp draw. All start-up and shutdown sequences are controlled by the PLC. If there is a problem, the unit will sound an audible alarm and shut the equipment down using the automatic sequenced shutdown program.
Plant configuration
With Kahler Automation's FDS-2850 tower control, the plant can wholesale fertilizer without a blender while the two blending towers are mixing product to order. VanOverbeke is proud of the fact that the two 200-ton towers by Yargus are stainless steel and made to last.
The two FDS-2850 tower units control all functions of the dry fertilizer weigh hoppers and mixers. One is capable of chemical impregnation. Batches are weighed and mixed automatically, allowing the plant operator to perform other duties. “It's incredible what we can move now,” VanOverbeke says.
The blenders are hooked to Kahler Automation controls. “That eliminates the fear of overshooting blends,” VanOverbeke says. “When people hold buttons, they can make mistakes. In peak season when the demand is heavy, computers don't get tired.”
Additionally, the agronomist in him appreciates that the analysis requested by the grower is going to be precise. That's important to customers who farm corn, soybeans, sugar beets and wheat in the Upper Midwest region that Tri-State services. When the growing season is short, speed and accuracy are critical.
A logical step
Automating their three fertilizer plants in Miller, Overton, and Riverdale, NE, seemed to be a logical step for Rick and Pat Bowie, owners and managers of Bowie Fertilizer. In 1967, Rick's father started the feed and fertilizer business, first selling anhydrous and then growing into solutions. Rick and his wife Pat bought the business in 1980 and subsequently expanded it to three locations.
As Bowie watched his business grow, it seemed he was always short on product. He knew he had to do something to get a better handle on this loss and looked into automating his plants. He first automated the main facility in Miller in the late '90s.
“It sped up our operation and increased accuracy,” Bowie says. Next was Riverdale. Both automated plants were so successful that Bowie wanted to expand his operation. The next step in his long-range growth plan was to construct a new, fully automated plant in Overton.
To do this, Bowie selected Junge Control. He was impressed with Junge's 26 years of expertise in automating fertilizer and chemical plants and its ability to devise the right mix of hardware and software that can be easily updated as new products or features are introduced.
To save on the overall cost of the new plant, Bowie was able to purchase a blender at an auction. To that, he added a 125-gal. Junge ChemWay, specially designed over the past 20 years for dispensing low quantities of crop protection products. When these products vary in value from $15 to $600/gal., it's important to watch the amount being measured. Fertilizer movement is controlled with a Junge MicroMotion mass flow meter.
The ChemWay system weighs crop protection product rather than metering it out. The mass flow meter ensures accurate fertilizer measurements and is quick.
Bowie is excited that customer satisfaction improved after he converted to an automation system. “A fertilizer and crop protection retailer has to make a lot of business decisions to grow, or even stay in business,” he says. “Our decision to automate has been the best one we've made yet.”
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