feedmill automation - petfoodindustry

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STERLING SYSTEMS & CONTROL, INC.PO Box 418 • 24711 Emerson Rd., Sterling, IL 61081

1-815-625-0852 • Toll Free: 1-800-257-7214 • [email protected]

FEEDMILL AUTOMATION

sterlingcontrols.com

(01/

19)

1-815-625-0852 • [email protected]

TOLL FREE: 1-800-257-7214

www.sterlingcontrols.com

LOADOUT

FEEDMILL AUTOMATION

Feedmill automation can simplify operation and improve effi ciency of cost

and throughput. Sterling Systems & Controls, Inc. custom designs and

manufactures the highest quality automation control systems for virtually any

Feedmill process or a complete facility.

Sterling Systems & Controls designs and provides equipment and software for

custom systems using Allen-Bradley PLC’s and desktop PC’s running Sterling

Systems’ customized Windows-based Automation Software. Sterling’s forty-

fi ve plus (45+) years of Feedmill process and Feedmill automation experience

ensures quality and effi ciency in both hardware and software.

LOADOUTAs with our other Feedmill automation application software, Sterling Systems’

Loadout system ensures the transport of the correct product to the desired

location, quickly and effi ciently, with superior accuracy.

With the ability to custom fi ll a truck with multiple orders the Loadout system

identifi es the load going into the truck trailer and then fi lls it with the correct

load.From beginning to end, Sterling Systems & Controls delivers accuracy and

dependability, validating that all product is loaded into the right truck, into

the right compartment and delivered to the right customer.

To accomplish the Loadout function accurately and effi ciently the truck

load out process screen (Figure 2) is used and typically consists of three

tables. The table located on the right lists all the truck compartments that

will be weighed into. The table located at the bottom right hand corner lists

only the loadout bins containing the calling formula order.

LOADOUT

APPLICATIONBenefi ts:

• Custom designed Loadout

software application to meet

your exact requirements

• Ensures feed delivery integrity

and validation

• Superior accuracy and

performance

• Easy to use, fl exible and

superior data management

Typical Features:

• Supports multiple trucks

and loads• Automatic truck profi ling

including using barcode and

RFID scanning

• Accurate weighments

• Loadout process operation,

graphic process fl ow and

control panel screens

• Multiple users and

programmable security profi les

• Tight integration with

batching system

• Report printing and

data exporting

• Ingredient bin inventory and

inventory transfer adjustments

• Integration with 3rd party

software is available

• Create or import loadout orders

• Control bin assignment


TOLL FREE: 1-800-257-7214











LOADOUTAs with our other Feedmill automation application software, Sterling Systems’

Loadout system ensures the transport of the correct product to the desired

location, quickly and effi ciently, with superior accuracy.

With the ability to custom fi ll a truck with multiple orders the Loadout system

identifi es the load going into the truck trailer and then fi lls it with the correct

From beginning to end, Sterling Systems & Controls delivers accuracy and

dependability, validating that all product is loaded into the right truck, into

the right compartment and delivered to the right customer.

To accomplish the Loadout function accurately and effi ciently the truck

load out process screen (Figure 2) is used and typically consists of three

tables. The table located on the right lists all the truck compartments that

will be weighed into. The table located at the bottom right hand corner lists

only the loadout bins containing the calling formula order.

(11/

18)


TOLL FREE: 1-800-257-7214


PELLETINGFEEDMILL AUTOMATION










PELLETINGWhile the pelleting process has historically been done manually, the Sterling

Systems & Controls pelleting system uses your production requirements and

formulas to create a customized and fully-automated pelleting process.

Upon starting the main pellet mill motor, the Pellet Mill control application

will start running the feeder at a predetermined speed when the idle

condition on the pellet mill motor is reached. The startup feeder speed is

determined by the hot or cold parameters. After the pellet mill electrical

current threshold value is reached (shown on main pellet mill screen), the

PELLETING APPLICATIONBenefi ts:• Custom designed Pellet Mill

control software application

to meet your exact automation

and system requirements

• Integrated mill monitoring and

histogram displays• Control functions maximize

throughput and high output;

mill optimized based on mill

condition• Plug conditions averted through

use of smart control, mill

shutdown automatic if plugged

conditions exist

Typical Features:• Control feeding, pelleting

throughput and rates• Graphic display of all key

parameters, including Mash

Temp, Feeder Rates, Steam, Mill

Current, etc.• Control wide range of Pellet Mill

types, quantities and sizes

• Smart control monitors mill

conditions.• Control group parameters can

vary widely depending on the

type of pellet mill• Parameters easily adjusted if

mill conditions change












While the pelleting process has historically been done manually, the Sterling

Systems & Controls pelleting system uses your production requirements and

formulas to create a customized and fully-automated pelleting process.

Upon starting the main pellet mill motor, the Pellet Mill control application

will start running the feeder at a predetermined speed when the idle

condition on the pellet mill motor is reached. The startup feeder speed is

determined by the hot or cold parameters. After the pellet mill electrical

current threshold value is reached (shown on main pellet mill screen), the

(11/

18)

1-815-625-0852 • [email protected] FREE: 1-800-257-7214www.sterlingcontrols.com

BATCHINGFEEDMILL AUTOMATION










BATCHINGSterling Systems & Controls, Inc. can automate your batching systems,

whether an ingredient multiple scale system provided by us or any other

vendor, or any type of weighing system for fi nished feed or feed in process.

Our batching control systems improve the effi ciency of your powder and

bulk, or liquid, material handling process.

We specialize in custom designed batching systems to increase performance,

consistency, eliminate waste, combine dry and liquid ingredients, and provide

unsurpassed production data collection and reporting capability.

The main operator interface of the Sterling Systems’ batching control

automation system is a desktop PC with Windows 10 operating system

running the Sterling custom designed batching application as well as a

custom database application. The PC and Sterling’ applications provide all

control, data storage, and equipment status information necessary to run the

batching process.

BATCHING APPLICATION

Benefi ts:• Custom designed software

application to meet your exact automation and system requirements

• Superior accuracy and performance; better throughput and high resolution possible

• Meet feed safety and traceability requirements

• Remote supervisory control and ERP system integration available

Typical Features:• Can incorporate multiple

ingredient applications of virtually any quantity, e.g. 20, 30, 40, more

• Virtually unlimited number of formulae

• Multiple scale designs easily accommodated

• Lot tracking, ingredient traceability and batch validation with barcode or RFID scanning available

• Variety of supply bin sizes, types, Including supporting bulk bags and totes

• Integrated control of a range of Mixer types, sizes and quantities


FEEDMILL AUTOMATION










BATCHINGSterling Systems & Controls, Inc. can automate your batching systems,

whether an ingredient multiple scale system provided by us or any other

vendor, or any type of weighing system for fi nished feed or feed in process.

Our batching control systems improve the effi ciency of your powder and

bulk, or liquid, material handling process.

We specialize in custom designed batching systems to increase performance,

consistency, eliminate waste, combine dry and liquid ingredients, and provide

unsurpassed production data collection and reporting capability.

The main operator interface of the Sterling Systems’ batching control

automation system is a desktop PC with Windows 10 operating system

running the Sterling custom designed batching application as well as a

custom database application. The PC and Sterling’ applications provide all

control, data storage, and equipment status information necessary to run the

(10

/18)


TOLL FREE: 1-800-257-7214


GRINDING

FEEDMILL AUTOMATION





Sterling Systems & Controls designs and provides equipment and software

for custom systems using Allen-Bradley PLC’s and desktop PC’s running

Sterling Systems’ customized Windows-based Automation Software.

Sterling’s forty-fi ve plus (45+) years of Feedmill process and Feedmill

automation experience ensures quality and effi ciency in both hardware and

software.

GRINDING

The Grinding process increases effi ciency and improves conditioning in a

feed production operation. Grinding performs particle size reduction for

further processing of the material. Grinding creates more surface area which

aids in digestion of the feed. In the grinding process fracturing of the solid

material occurs, resulting in both an increase in material surface area and

dissipation of heat.

Whether you use a roller mill, hammermill or something else in your process,

Sterling Systems & Controls, Inc. automation and process control systems

can automatically optimize its operation within the overall feed production

process and automation system to meet a specifi c size requirement; adjusting

the gaps in roller mills to meet a specifi c micron size. This also includes

setting or programming Mill Type, Grinding Rate, Loss Factor and Source/

Destination Ingredient, along with providing feeder speed control based

GRINDING

APPLICATION

Benefi ts:

• Higher accuracy and superior

product

• Automatic adjustment of

Grinders to meet particle size

requirement

• Reduced waste and

contamination

• Runs Grinders automatically

to keep destination ingredient

bins full

Typical Features:

• Easily set Mill Type, Grinding

Rate, Loss Factor, Source /

Destination Ingredients

• Automatic scheduling and

transfer of materials

• Maximizes throughput by

running grinding mills to the

most effi cient load

• Grinds whole ingredients and

routes them to the correct

bins, with little or no attention

from an operator

• Tracks maintenance minder

data; hours, tons of usage

• Mill monitors integrated into

Feedmill automation system

• Blend multiple Source

ingredients to produce a single

ground Destination ingredient


TOLL FREE: 1-800-257-7214






Sterling Systems & Controls designs and provides equipment and software

for custom systems using Allen-Bradley PLC’s and desktop PC’s running

Sterling Systems’ customized Windows-based Automation Software.

Sterling’s forty-fi ve plus (45+) years of Feedmill process and Feedmill

automation experience ensures quality and effi ciency in both hardware and

software.

GRINDING

The Grinding process increases effi ciency and improves conditioning in a

feed production operation. Grinding performs particle size reduction for

further processing of the material. Grinding creates more surface area which

aids in digestion of the feed. In the grinding process fracturing of the solid

material occurs, resulting in both an increase in material surface area and

dissipation of heat.

Whether you use a roller mill, hammermill or something else in your process,

Sterling Systems & Controls, Inc. automation and process control systems

can automatically optimize its operation within the overall feed production

process and automation system to meet a specifi c size requirement; adjusting

the gaps in roller mills to meet a specifi c micron size. This also includes

setting or programming Mill Type, Grinding Rate, Loss Factor and Source/

Destination Ingredient, along with providing feeder speed control based

GRINDING

APPLICATION

Benefi ts:

• Higher accuracy and superior

product

• Automatic adjustment of

Grinders to meet particle size

requirement

• Reduced waste and

contamination

• Runs Grinders automatically

to keep destination ingredient

bins full

Typical Features:

• Easily set Mill Type, Grinding

Rate, Loss Factor, Source /

Destination Ingredients

• Automatic scheduling and

transfer of materials

• Maximizes throughput by

running grinding mills to the

most effi cient load

• Grinds whole ingredients and

routes them to the correct

bins, with little or no attention

from an operator

• Tracks maintenance minder

data; hours, tons of usage

• Mill monitors integrated into

Feedmill automation system

• Blend multiple Source

ingredients to produce a single

ground Destination ingredient

(10/1

8)

1-815-625-0

852 • sci@

sterlin

gcontrols.c

om

TOLL FREE: 1-800-257-7214

www.sterlin

gcontrols.c

om

RECEIVING / TRANSFER

FEEDMILL AUTOMATION

Feedmill automatio

n can simplify

operation and im

prove effi ciency of c

ost

and throughput.

Sterling Syste

ms & Contro

ls, Inc. custo

m designs a

nd

manufactures the highest

quality automatio

n control sy

stems f

or virtu

ally any

Feedmill process

or a complete fa

cility.

Sterling Syste

ms & Contro

ls desig

ns and provides e

quipment and so

ftware fo

r

custom sy

stems u

sing Alle

n-Bradley PLC’s a

nd desktop PC’s running Sterlin

g

Systems’ c

ustomize

d Windows-b

ased Automation Softw

are.

Sterling’s f

orty-fi v

e plus (45+) y

ears of F

eedmill process

and Feedmill

automation experie

nce ensures q

uality and effi c

iency in both hardware and

softw

are.

RECEIVING / TRANSFER

The Receiving/Transfer a

pplication is

custom desig

ned to su

it your e

xact

needs. This i

ncludes allo

wing for o

nly manual contro

l or in

cluding the abilit

y to

allow fo

r automatic

receiving and tra

nsfer s

teps.

A fully automatic

Receiving & Transfer a

pplication accurately tra

cks and

transfe

rs incoming grain and commodity

materia

ls to th

e correct lo

cation

within your fa

cility each and every tim

e.

Truck or Railcar tr

ansport

of incoming m

aterials c

an be accommodated.

Feed rates a

re controlle

d to m

aximize

effi ciency and m

aterial sa

fety. Afte

r

the materia

l has b

een moved in

to the containment lo

cation (b

in etc.) the

system lo

gs and w

eighs empty tru

cks before th

ey leave th

e facilit

y. Weight

measurements

are logged in

to the m

aterial tr

acking functio

n, maintaining

accuracy and traceabilit

y.

RECEIVING/

TRANSFER

APPLICATION

Benefi ts:

• Faste

r off-

loading of grain

and commodities

• Meet tr

aceability and

validatio

n require

ments

with m

aterial tr

acking

• Bette

r reports

for

management; by vendor,

farmer, t

ruck/rail c

ompany

• More effi c

ient, greater

productivity

due to easy

operation and bette

r knowledge

of what y

ou have and where it

is

Typical Features:

• Receive m

aterials b

y truck or ra

il

• Automated ro

uting – i

nterlocks

or manual o

peration

• Include sh

ipping and

transfe

r functio

ns

• Sim

ple data entry

• Modern graphic disp

lays

• “Point &

Click” m

ovement of

material fr

om point A to

B

• Integrate w

ith ERP sy

stem or

other third

party so

ftware

• Grin

ding and Use bins auto

refi ll w

ith le

vel indicatio

n

24/7 SERVICE & SUPPORTWe don’t leave you hanging, and there are no annual contracts required. If you call for service or technical support because of some problem you are experiencing, our focus is getting you back up and running as quickly as we can. To best service you we make sure you can report your problem and we are available to work on your problem at any time of day, any day of the week, 24/7. Some of our competitors require annual contracts and/or a PO before they will even speak with you, that is putting their needs ahead of yours. Not here at Sterling Systems & Controls, getting your problem solved and getting your production back up and running is our fi rst priority.

PELLETINGWhile the pelleting process has historically been done manually, the Sterling Systems & Controls pelleting system uses your production requirements and formulas to create a customized and fully-automated pelleting process.

SUPERIOR APPLICATION PERFORMANCE - Custom design ensures the Pellet Mill automation application is just what you need and want, ensuring optimum operation, maximizing throughput and mill output.

DEPENDABLE MILL OPERATION ENSURED - Pellet Mill application monitors key mill operation and functions and ensures dependability and maximizes up time.

BATCHINGSterling Systems & Controls, Inc. can automate your batching systems, whether an ingredient multiple scale system provided by us or any other vendor, or any type of weighing system for fi nished feed or feed in process. Our batching control systems improve the effi ciency of your powder and bulk, or liquid, material handling process.

SUPERIOR APPLICATION PERFORMANCE - Custom design ensures the automation system is just what you need and want, while ensuring the maximum performance in terms of accuracy and throughput effi ciency.

INTEGRATING WITH EXISTING SYSTEMS - Remote supervisory control using WebCentral™ application software allows for easy-to-use browser-based operation and report generation. Exporting data to integrate with corporate ERP systems is available.

MATERIAL TRACEABILITY & BATCH VALIDATION - Feed safety, Petfood and foodstuffs for human consumption as well, are of paramount importance. Ingredient material traceability with simple-to-comprehensive lot tracking tools, and batch validation will help you meet safety standards and requirements. Barcode and RFID scanning capability can be provided.

Serving your processing needs for over 45 years.STERLING SYSTEMS & CONTROL, INC.PO Box 418 • 24711 Emerson Rd., Sterling, IL 61081

1-815-625-0852 • Toll Free: 1-800-257-7214 • [email protected]

LOADOUTAs with our other Feedmill automation application software, Sterling Systems’ Loadout system ensures the transport of the correct product to the desired location, quickly and effi ciently, with superior accuracy.

With the ability to custom fi ll a truck with multiple orders the Loadout system identifi es the load going into the truck trailer and then fi lls it with the correct load.

SUPERIOR APPLICATION PERFORMANCE - Custom designed Loadout software application to meet your exact requirements, and ensures feed delivery integrity and validation.

SUPERIOR ACCURACY AND EASE OF USE - Superior accuracy and performance, data management, report generation and exporting, and simple menu driven screens are easy to use and understand.

RECEIVING / TRANSFERThe Receiving/Transfer application is custom designed to suit your exact needs. This includes allowing for only manual control or including the ability to allow for automatic receiving and transfer steps. A fully automatic Receiving & Transfer application accurately tracks and transfers incoming grain and commodity materials to the correct location within your facility each and every time.

FAST OFF-LOADING OF MATERIALS - More effi cient receiving and transfer of incoming materials means higher throughput and production, as well as lower labor costs.

SUPERIOR REPORTS - information is stored in a database by farmer, vendor, truck/rail company, etc. allowing you to provide custom reports.

KNOWING WHAT YOU HAVE & WHERE IT IS - Traceability, lot tracking and batch validation is enhanced. Less errors and increased effi ciency means greater profi tability.

FEEDMILL AUTOMATIONFeedmill automation can simplify operation and improve effi ciency of cost






Systems’ customized Windows-based Automation Software.

Sterling’s forty-fi ve plus (45+) years of Feedmill process

and Feedmill automation experience ensures quality

and effi ciency in both hardware and software.

GRINDINGThe Grinding process increases effi ciency and improves conditioning in a feed production operation. Grinding performs particle size reduction for further processing of the material. Grinding creates more surface area which aids in digestion of the feed. In the grinding process fracturing of the solid material occurs, resulting in both an increase in material surface area and dissipation of heat.

HIGHER ACCURACY & SUPERIOR PRODUCT - Automatic optimization of your Grinders to meet your specifi ed particle size; manage grinding rate, loss factor and mill functionality to produce a superior ground product with a greater level of accuracy of the ground ingredient.

REDUCED WASTE & CONTAMINATION - With automatic scheduling and control of your particle reduction process the Grinding application automatically adjusts Grinders to work accurately and quickly, reducing waste and contamination.

RUN AUTOMATICALLY, KEEP GROUND BINS FULL – Automated scheduling of grinding and transfer processes ensures destination ingredient bins remain full.

feedmill automation - petfoodindustry

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