Project SHOWCASE

When these facilities needed process control, they called Kahler Automation. Look through the features below to learn about some of the thousands of projects Kahler has had a role in automating over the past 25+ years. More project showcases coming soon...


THE EQUITY — ALMA, ILLINOIS

PROJECT: The Equity, Alma, IL

“It was a privilege to bring another blending facility online for The Equity. They are clearly dedicated to bringing best-in-class technology to customers across their entire family of agronomy sites. Working with their team on a complex facility like Alma was a truly rewarding experience, and we look forward to further partnering with The Equity as they serve southern Illinois growers.”

Tim Glienke
Territory Sales Manager
Kahler Automation

The Equity was constructing a new chemical building to replace an outdated facility in Alma, Ill., and wanted a liquid automation system to serve its needs not just for today but for a decade to come. The rising cost of crop inputs made inventory management a critical piece of a new system; reducing inventory shrink presented an opportunity to enhance The Equity’s return on investment.

The system had to be fast, accurate, and fully integrated. They needed to keep sprayers moving in the field to increase efficiency. Hot loading tenders quickly and accurately for multiple fields and sprayers was a must, ultimately reducing the need for additional equipment to service customers. With crop inputs constantly changing, the Alma facility required the ability to quickly adapt to the dynamic agronomy environment. And The Equity’s call for efficiency and speed required trucks to continue loading top or bottom in two bays while still receiving product in the third.

“The Equity has numerous locations with Kahler Automation systems in place, with more scheduled for installation by next spring. Our main reasons for going with Kahler systems are the reliability and functionality; beyond that, they deliver accurately and efficiently at high speed, resulting in notable cost savings. Kahler Automation’s support is the best, and the people there go above and beyond to solve any issues. We love the integration into our crops software, saving so much back office work.”

Wes Ware
Facility & Project Manager
The Equity

Kahler Automation answered the call. Our powerful software tracks every transaction, from order inception to delivery and invoicing. Not a drop of product leaves the facility without The Equity knowing how much, where it is going, and who is paying for the product. All of the tracking is done electronically, with very little if any paper shuffling or multiple data entry points.

Using highly accurate instruments and cutting-edge technology we are able to dispense multiple chemicals and fertilizers into a mix batch simultaneously — no waiting for scales to settle or product to discharge before moving to the next step in the sequence. All systems are integrated into one ultimate package, operating multiple pieces of equipment super-efficiently to save time and money.

Kahler Automation created a flexible and robust control system for the Alma facility, using the best components in the industry, but our relationship with them didn’t end at startup. Not only does The Equity’s system allow our support staff to access and update controls remotely — providing support in minutes — if they should ever require emergency hands-on assistance, they know that a Kahler field technician can be at their site in a matter of hours, courtesy of our fleet of support aircraft.


LUCKEY FARMERS INC. — BRADNER, OHIO

PROJECT: Luckey Farmers Inc., Bradner, OH

The customer was looking at designing a facility very similar to its Graytown location, with a few modifications. Luckey Farmers had an existing UAN tank on-site that was not automated; the tank was in a good location to serve current customers and grow with them as they expanded. The company wanted to add a 24/7 bay to allow it to serve its customers without an employee on-site.

In addition, it needed other liquid fertilizers to do some blending, as well as chemical dispensing that would utilize bulk chemical tanks and shuttles. All of this had to interface with its existing agronomy and accounting software to make billing easier and less time-consuming.

Kahler Automation started with the design from Luckey Farmers’ Graytown, OH, location, adding a 24/7 bay for a total of three bays. We used separate meters for each bay so they had the ability to simultaneously dispense straight product or splash-blend in the truck out of all bays at the same time.

We also provided meters for the bulk chemicals, so they could inject into the carrier line for hot loading or divert to pistol grips to fill shuttles or trucks. We provided a weigh tank with the ability to inject chemicals from shuttles or hand-added materials for hot loading on less-used products. Kahler Automation provided a pre-wired motor control center that saved labor and simplified the electricians’ job onsite.

Kahler’s Terminal Management and Plant Supervisor software were able to interface to their accounting package, tying everything together and reducing paperwork for their office staff. Luckey Farmers is able to successfully stage  orders allowing them to maximize use of all three bays at once.


UNITED FARMERS Cooperative — BROWNTON, MINNESOTA

PROJECT: United Farmers Cooperative, Brownton, MN

In collaboration with Sackett Waconia, a 200-ton blend tower with four-ton high-intensity mixer (HIM) was developed; a liquid impregnation system was designed by Kahler. An accompanying straight product tower allows wholesale trucks to be loaded quickly. 

A custom chemical and liquid fertilizer facility was designed for prescription blends to be made. Both straight product and hot loading is available.

To meet United Farmers Cooperative’s lofty efficiency goals Kahler Automation’s designs included a 24/7 unstaffed load-out bay, with technology allowing UFC customers to pick up scheduled fertilizer orders at any time, day or night.

Partners: Sackett-Waconia / SMA, LLCA&B Welding / Anderson Electric of Lamberton


Heritage Cooperative — Marysville, OHIO

PROJECT: Heritage Cooperative, Marysville, OH

To meet the challenging goals of Heritage Cooperative, Kahler Automation designed a facility that included a 24/7 unstaffed loadout bay with technology that enables customers to pick up fertilizer 24 hours a day.

A 200-ton blend tower with 3-ton High Intensity Mixer was developed with Kahler designing a liquid impregnation system. Liquids can be sprayed simultaneously so speed is not compromised when impregnating. 

Kahler Automation's grain system allows the entire grain operation to be monitored and controlled from anywhere on the control network. Grain can be moved anywhere in the facility by multiple source/destination selections, controlled by a touchscreen, requiring only one person. 

Partners: Stueve Construction (dry fertilizer design & construction) / AJ Sackett & Sons (blend tower) / A&B Welding (process plumbing)