Dry Fertilizer & Liquid Agronomy Automation
New Dry Fertilizer Multi-Bin System With Orbital Mixer & Liquid Loadout Retrofit
PROJECT: AgVantage FS, Mechanicsville, Iowa
OVERVIEW
From the new build to retrofit solution, AgVantage FS has enhanced the speed and efficiency of their dry and liquid loadout operations to meet current and future demand more effectively. The liquid system design features many process improvements that leverage our team’s knowledge, experience, and expertise. From hardware to software, the system has improved inventory accuracy, reducing shrinkage while providing more streamlined business management with expedited invoicing and reporting.
WHAT THEY NEEDED
AgVantage FS needed to update its dry and liquid agronomy center to handle both present demand and the future needs of customers. The company needed to update its inefficient dry fertilizer facility with a cost-effective solution to provide excellent blend quality and increased capacity. AgVantage FS also wanted to expand its offerings with additional dry products to provide a wider range of blend options for customers.
On the liquid side, AgVantage FS needed faster loadout and accuracy to match the pace of their applicators. The company needed a high-quality custom solution to maximize the efficiency of existing building design systems and avoid the need for a complete overhaul. Several aspects of the operation, including the repack process and billing, were inefficient and time-consuming. AgVantage FS needed to clearly understand inventory to help improve its business management and integration with Agvance.
WHAT WE DESIGNED
The initial project objective was construction of a new dry fertilizer building, with subsequent retrofit upgrades to the liquid fertilizer and crop protection building. We evaluated the facility’s overall cost of ownership and performance; we took into account both the liquid and dry components to provide seamless integration. The state-of-the-art dry facility supplies five different outlets in their region. The system is set up for 11 products plus swing products for precise blending. The motor control center with terminal nest offers quick and easy setup for onsite service.
The liquid system features legal-for-trade mass flow meters for each chemical, so that everything can be run simultaneously to speed up loadout. Controls and software are common throughout this location, allowing for flexible staffing with more internal knowledge and easy product training. Electronic order integration provides a paperless process, eliminating manual entry errors for fast and accurate accounting.
Specs At A Glance
GENERAL
Business Name & Location: AgVantage FS in Mechanicsville, Iowa
Type of Business: Retail
Products Offered: Dry Fertilizer, Liquid Fertilizer, Crop Protection Chemicals
Total Acres: 2.4
Total Square Feet: 104,000
Receive Product Via: Truck
LIQUID FERTILIZER & CROP PROTECTION
Liquid Fertilizer Storage Capacity: 120,000 gallons in 5 tanks
Type of Liquids Stored: 28% and Ammonium Thiosulfate (ATS)
Tonnage per Hour: 100
Number of Trucks per Hour: 6
Bulk Chemical Storage Capacity: 8 tanks, 8 totes for over 24,000 gallons
Loadout Capacity: Up to 400 GPM
Number of Operators Required: 1
Control System: Kahler Automation
DRY FERTILIZER
Dry Fertilizer Storage Capacity: 8,330 tons
Number of Storage Bins: 6
Total Tons per Year: 12,600
Total Tons per Day: 250 to 300
Tons per Hour: 65
Receiving Capacity: 200 TPH
Loadout Capacity: 100 to 250 TPH
Blending Type: Orbital
Number of Materials in Typical Blend: 2-4
Micronutrients: 3
Impregnation: Yes, 2
Batch Sizes Offered: Any combination
Number of Trucks per Hour: 5
Truck Scale: Not required
Number of Operators Required: 1
Control System: Kahler Automation
WHAT THEY HAD TO SAY
Brad Newhard, Dry Shed Operator, AgVantage FS:
“We have spot-on loading, our weights come out right, our inventory comes out right. We can blend a lot more products. We only had two products before and now we have seven. Productivity is better than I ever expected.”
Angie Dusanek, Admin, AgVantage FS:
“Most of my job is billing for the chemical, seed, and fertilizer. With the old system … there was a lot of manual adding which ups the risk of counting errors and things like that. The new Kahler system … has made that quicker. The nice thing is it comes in automatically.”
