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Company Name: Farmers Coop Society
Location: Sioux Center, Iowa
Upgrade: Automated fertilizer blending and loadout system
“With our old batch mixer we were looking at anywhere from 20 to 40 minutes… down to 10 minutes now for a semi-load.”
— Tim Zeutenhorst, Assistant Manager of Agronomy Operations, Farmers Coop Society
Key Results
- Reduced load times from 20–40 minutes to ~10 minutes per semi-load
- Improved operational efficiency and throughput
- Reduced labor requirements to a one-person operation
- Eliminated slow, manual batch mixing processes
The Challenge
Prior to implementing automation, Farmers Coop Society relied on a batch mixing system that was slow, labor-intensive, and inefficient.
Depending on the blend, each load could take anywhere from 20 to 40 minutes to complete. The process also required multiple operators, making it difficult to maintain efficiency during busy seasons.
To improve productivity and reduce labor demands, the team needed a solution that could streamline blending operations while significantly reducing load times.
Why Kahler Automation
Farmers Coop Society selected Kahler Automation to modernize its blending process and improve overall operational efficiency.
The goal was to implement a system that could eliminate manual steps, reduce labor requirements, and provide a faster, more consistent blending process.
The Results
Since implementing Kahler Automation, Farmers Coop Society has seen significant improvements in both speed and efficiency.
Load times have been reduced from 20–40 minutes per batch to approximately 10 minutes per semi-load, allowing the facility to move product much faster and keep up with demand.
Automation has also reduced labor requirements. What once required two or more operators can now be managed as a one-person operation, freeing up staff and simplifying day-to-day operations.
These improvements have helped the facility operate more efficiently while increasing overall throughput.
Simplified Operations and Efficiency
With Kahler Automation in place, Farmers Coop Society has transformed a previously slow and labor-intensive process into a streamlined, efficient operation.
The system allows the team to produce fertilizer blends faster, with fewer resources, and with greater consistency — helping the operation stay productive during peak seasons.
