FEATURE Drives, motors & controls
Technidrive’s automation system offers a more sustainable and cost-effective approach for the milling industry
Strike a balance O
Gary Kernaghan, automation manager, Technidrive, explains how automating a feed mill reduces energy costs and preserves quality
ptimising milling systems by reducing energy consumption can improve operations in more ways
than one. Automating a feed mill could be the key to unlocking energy efficiency and substantial cost savings, and can be done by controlling the speed of the machine that feeds the product into the mill. From pulp and paper to flour and grain, there is now an increasing emphasis on optimising operations, minimising environmental impact, and reducing costs.
As an example, take ADM, one of the world’s largest nutrition companies. Its Strive 35 initiative aims to reduce absolute greenhouse gas emissions by 25 per cent, energy intensity by 15 per cent, water intensity by 10 per cent, and attain a 90 per cent landfill diversion rate, all by 2035. Energy use plays a significant
role in determining the costs related to producing feed for poultry and livestock. In fact, a typical feed mill producing 250,000 tonnes of feed per year can spend as much as £750,000 a year on energy, according to Finning. There are numerous strategies that aim to enhance efficiency, however, turning to automation stands out as one
28 October 2024 | Automation
of the most effective approaches. Automating a feed plant allows manufacturers to ensure a minimal margin of error throughout the entire processing and packaging procedure. In order to process a range of different animal feed products, mill feeding systems require regular speed adjustment. Feeding systems are responsible for transporting material into the mill itself, where grains, seeds and other raw materials are ground into smaller particles or powders. Mills that introduce automation systems, capable of adjusting feeding speed to the desired level, not only achieve a reduction in energy usage, but also contribute to enhanced sustainability practices. In contrast, a feeding system reliant on manual labour, can struggle to strike the right balance when adjusting feeder speed. This could lead to prolonged shifts and wasted energy if the speed is too slow and compromised feed quality if the feed rate is excessively fast. Implementing a consistently efficient feeding process, enables feed manufacturers to improve throughput during each shift and minimise overall running time. Furthermore, a system operating consistently at its peak performance level, not only conserves time but also allows facilities managers to divert their attention to other crucial aspects of the manufacturing
process. This includes compliance with safety regulations and coordination with suppliers and distributors. By curbing energy consumption, manufacturers can effectively trim operational expenses, therefore enhancing their overall financial performance. The adaptability offered by automated speed control, optimises energy usage without compromising operational efficiency. This results in improved product quality through optimal grinding, and a reduction in overall plant running hours, further contributing to sustainable milling practices. Bespoke solutions can leverage control algorithms and precision engineering to seamlessly modulate feed mill speeds. This approach ensures a fine balance between energy savings and the preservation of feed quality and consistency. Sophisticated motor control technologies play a crucial role in achieving these outcomes.
Beyond immediate cost savings, the impact of energy-efficient milling minimises maintenance requirements and improves the longevity of milling equipment. In response to industry needs, Technidrive has developed an innovative automation solution designed to optimise feed mill operations. At its core is the implementation of advanced variable speed drive (VSD) technology, which precisely controls motor speed to streamline the milling feed process. This solution was integrated at Kerry Agribusiness, resulting in a 29 per cent increase in throughput from the mill since the installation. The automation system replaced traditional manual controls with a software interface, enabling seamless remote monitoring and control. Eliminating the need for trial-and-error adjustments, operators gain real-time insights into milling operations.
Enhanced by a smart algorithm, the system dynamically adjusts the feeder’s speed, striking a balance between energy savings and operational efficiency, and translating into more sustainable and cost-effective milling.
CONTACT:
Technidrive
www.technidrive.co.uk
automationmagazine.co.uk
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