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Agri-Industry - including Animal Feed

The weight of wheat Precia-Molen GeneSYS Enterprise system provides the complete solution

for Ensus

Precia-Molen has just installed GeneSYS software for Ensus at its Biorefinery site, at Wilton, Teesside providing a total management system for its grain intake operation. The Wilton operation is one of the largest in the world and provides a vehicle unloading and intake facility for in excess of 1.2 million tonnes per annum of wheat. Ensus produces a significant part of the UK’s Bioethanol demand under the UK’s Renewable Transport Fuel Obligation (RTFO), and generates carbon savings equivalent to taking 300,000 cars off the road. As one of Europe’s largest producers of animal feed materials the 350,000 tonnes of high protein animal feed produced each year reduces UK and European demand for soy meal imports that contribute to deforestation pressures in South America.

The group raised £250 million to build the plant at Wilton, and a further £60m investment has been made by related parties. These investments support over 2000 jobs in the UK’s farming, logistics and manufacturing industries, and accelerate the development of the North East UK region as a new green industrial hub.

Ensus chose the Precia-Molen GeneSYS software package because it met four key criteria: • To bring the entire vehicle unloading operation, including contract validation, sampling, laboratory testing, weighing and discharge on two Precia-Molen weighbridges under the control of a single PC network. • To be fast enough to cope with a very tight site layout. With an incoming vehicle every 3 minutes it is crucial that the system is fast enough to ensure that they have all been tested and accepted for delivery by the time they arrive at the weighbridge. • To be flexible enough to adapt to the changing needs of Ensus, allowing new commodities to be added to the database if necessary. • To be fully supported with technical back-up and updates.

Consequently, Precia-Molen installed multi-user GeneSYS Enterprise on the existing Ensus network. All the GeneSYS applications communicate with a single Microsoft SQL database, which is installed on the dedicated server. Traffic enters the site at the booking-in terminal with the driver gaining access by receiving a card from the Precia-Molen automatic card dispenser. Selecting one of four traffic lanes the driver is directed by overhead electronic signage to the un- sheeting area.

The truck then moves forward to the two stations in the grain sampling building, here the driver inserts the delivery documentation into a vacuum dispatch system which delivers it to the sample probe operator in the laboratory above. The operator enters the relevant information including reference number, vehicle registration, and contractor code and commodity type. GeneSYS then retrieves the contract details form the database and checks that the transaction is valid. If it is accepted the driver then moves forward to the sampling position where a sample is drawn off by one of two remotely operated vacuum spear samplers and sent to the laboratory above for testing.

By the time the sample arrives at the laboratory, GeneSYS will already have printed off a sample document with a check list of the quality tests required for this load. The results of each test are fed in by laboratory staff and automatically checked against the pass/fail criteria. If the sample passes all the quality tests then the vehicle is given permission to unload. If the sample fails for any reason then the vehicle is put on ‘waiting’ status and the test details are flagged up on the screen. This allows staff to contact the supplier to inform them the load has been rejected, or to negotiate acceptance below contract specification. Drawing forward the driver then re-sheets the load, and proceeds to the driver console where having swiped his card he receives either a pass or fail. On receiving a pass (if a fail exit the site) he proceeds to the truck control lights to await clearance to

24 Solids & Bulk Handling • October 2011

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