2 min read
More Loads, Shorter Days: How Automation Transformed Operations at Ehler Brothers
Company Name: Ehler Brothers Co.
Location: Thomasboro, Illinois
Upgrade: Liquid plant upgrade, utilizing existing building and tanks
Key Result(s):
-
3× increase in truck loading speed
-
Expanded capacity that helped double the business in four years
-
Shorter operating days and improved employee quality of life
The Challenge:
Ehler Brothers’ existing liquid loadout system was more than 40 years old and limited to a single load bay. As the business continued to grow, the outdated system became a bottleneck — restricting throughput, extending workdays, and putting a ceiling on future expansion.
To support continued growth, Ehler Brothers needed a modern, automated dual-load bay facility that could increase speed, improve efficiency, and scale with future demand.
Why Kahler Automation:
The decision to partner with Kahler Automation was driven by both experience and comparison.
One member of the Ehler Brothers team had previously worked with a Kahler system, which provided immediate confidence in the platform. In addition, the team toured several nearby facilities using competing systems and evaluated both automation software and building designs.
After seeing those alternatives firsthand, it was clear that Kahler stood apart. Kahler’s software offered superior functionality, ease of operation, and reliability. Most importantly, the system enabled Ehler Brothers to operate at maximum capacity while
keeping customers, drivers, and operators satisfied — a critical factor in the company’s success.
The Results:
The most significant improvement delivered by the Kahler Automation system was loading speed.
Each semi-truck load averages approximately 5,000 gallons. Under the previous system, Ehler Brothers could load only about two trucks per hour. With the new dual loadout and Kahler Automation system, the facility now averages six loads per hour — a 3× increase in throughput.
This increase has dramatically reduced downtime for application equipment in the field. The less time machines sit idle, the more productive — and profitable — the operation becomes.
Four years after commissioning the new facility, Ehler Brothers has continued to expand, and this upgraded plant alone has helped the business double in size.
Return on Investment
Before the upgrade, long operating hours were the norm. The team routinely started work around 4:30 a.m. and didn’t finish until 9:00 p.m. just to keep up with demand.
Today, with Kahler Automation and a dual loadout system in place, the workday typically runs from 6:30 a.m. to 7:00 p.m., while still covering more acres and handling higher volumes.
While the gains in speed and capacity are substantial, the most meaningful return on investment has been the impact on employees. Getting team members home earlier and spending more time with their families aligns directly with Ehler Brothers’ values — and contributes to long-term business success.
