In any industry, automation is based on goals: solving problems, minimizing risks, and reducing costs. The same is true for feed mill automation. There are a number of ways that feed mill automation can improve the end product and solve or reduce problems throughout the operation. Though some facilities may automate all processes at once, step-by-step automation is also a viable option. Feed mill automation can drive ROI in the following ways, and many of these benefits may occur simultaneously, depending on which process or processes you choose to automate.
7 Ways Feed Mill Automation Drives ROI
1. Reducing Labor Costs
Automation not only ensures that tasks are completed consistently, but also eliminates the need for manual operation. Repetitive tasks no longer require physical labor, and free up manpower for more sophisticated and important jobs. Automation can also protect workers from safety risks, either by removing them from dirty or dangerous environments, or by putting reliable safety controls in place.
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2. Enhanced Production
Enhanced production is one of the most common factors driving ROI in feed mill automation. With the right design and maintenance, automation can streamline processes and remove the need for breaks and pauses. The right machines can also work at a faster rate.
3. Measureable Regulatory Compliance
Feed mill automation can simplify regulatory compliance for rules like the Food Safety Modernization Act (FSMA), among others. Track and trace is an important part of FSMA compliance, but can be difficult to accurately implement without systematic controls. Tracking lot numbers manually not only introduces error, but takes up workers’ time and energy. Lot tracing can easily be automated, and it will greatly improve accuracy. With a reliable, automatic system in place tracking where your ingredients came from, what they went into, and where the product ultimately went, you can reduce liability and meet compliance requirements with minimal costs.
4. Consistent Testing
To prevent moisture, toxins and other substances from ruining ingredients and the finished product, proper sampling and testing is essential. With automated sampling and testing, you can gather uniform, accurate information about ingredients and products. Detecting excessive moisture in ingredients from the start will prevent product from being contaminated, and allow you to hold suppliers accountable for defects. Detecting aflatoxins and other harmful substances in ingredients also reduces liability, as well as product loss. With feed mill automation for testing and sampling combined with automated track and tracing, any problems with ingredients or products can be accurately recorded.
5. Reducing Batching Errors
Batching is one of the most common areas for feed mill automation, and often offers the highest initial ROI. By automating your batching and mixing processes, you can substantially reduce error and variation. When your recipe is programmatically controlled, corn, soy, vitamins, minerals, enzymes and other additives are each exactly measured. With an easily re-programmable controller, you can even change the recipe without significant downtime.
6. Automatic Routing
Automation of the batching process is usually the first section of the feed mill to be automated, but the addition of downstream routing of material can enhance the payback of the system. If the system has to wait for the operator to setup the routing of material to the downstream packaging or load-out, then valuable production time can elapse while waiting for a route to be selected.
Through most zones, feed mill automation makes hazard analysis and critical control points easier to regulate and monitor. By gathering more data, more often, with less manpower required, you can get holistic, up-to-date information about your production line. You can also eliminate risks altogether by automating repetitive tasks with a high risk of human error. Automated regulation ensures that critical control points are monitored at the same time, in the same way, with no exceptions.
Before starting or continuing feed mill automation, plan and design your system carefully. Conduct ingredient testing to ensure that the system is suitable for your recipe, and be sure to factor any maintenance costs into your ROI calculations. With the right system automating the right process, you can realize a return quickly and eliminate risks at the same time.