Kerry Agribusiness has embraced agricultural automation, leveraging cutting-edge automation equipment to streamline operations at its feed mill.
Feed production in Ireland’s agricultural sector is projected to be worth €845.1 million by 2026. However, with feed manufacturing responsible for 50–75% of energy consumption in the EU’s livestock sectors, there’s significant pressure on agricultural businesses to improve efficiency. To address these challenges, Kerry Agribusiness collaborated with Technidrive to automate its feed mill in Farranfore, County Kerry.
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Challenges of Manual Feed Mill Operations
The feed mill processes raw ingredients such as grains, seeds, and other components into smaller particles or powders. This step is crucial in animal feed production, ensuring a consistent particle size suitable for livestock consumption.
However, manual adjustments to the feeding system presented several challenges:
- Operators had to be on-site during production runs to alter feeder speed manually.
- Adjustments relied on trial and error, based on past experiences.
- Slow feed rates led to inefficiencies, longer production times, and wasted energy.
- Fast feed rates resulted in subpar feed quality, with oversized particles affecting nutritional value.
The need for an automated system became evident to improve speed adjustments, optimize milling processes, and enhance the quality of feed.
The Automated Solution by Technidrive
Technidrive, a Northern Ireland-based systems integrator, provided a tailored automation solution powered by WEG technology. The company recommended the WEG CFW11 inverter to control the feeder motor, allowing precise speed adjustments for optimal efficiency and quality.
The manual controls were replaced with a software-based system using the WEG Ladder Programmer (WLP) interface. This transition offered:
- Remote monitoring capabilities
- Insight into feed mill operations
- Elimination of manual adjustments
To ensure seamless operation, Technidrive engineers modified the feeder control circuit board, enabling a broader speed range. The system was further enhanced with a smart algorithm to automatically adjust feeder speed based on setpoints.
The Benefits of Feed Mill Automation
Since the automation system’s installation in June 2022, Kerry Agribusiness has seen significant improvements:
- A 29% increase in throughput.
- Energy savings due to optimal feeder speed adjustments.
- Reduced reliance on manual intervention.
These results have inspired Kerry Agribusiness to explore further automation projects across its operations.
Driving the Future with Agricultural Automation
“We’ve seen remarkable efficiency improvements,” said Gary Kernaghan, automation manager at Technidrive. “The automated system has reduced energy costs and significantly increased productivity.”
Stephen O’Regan, a nutritionist, added, “We’re driving the grinders harder now. They were always mechanically capable but lacked the electrical capability. Thanks to feed mill automation, we’re saving time and achieving better results. We’re now exploring further upgrades for other systems, including pellet presses and coolers.”
This success underscores the transformative potential of agricultural automation. By adopting data-driven, automated approaches, agricultural businesses can optimise efficiency, reduce energy consumption, and ensure sustainability in feed production.
Conclusion
The success of Kerry Agribusiness’s feed mill project exemplifies the growing impact of agricultural automation and feed mill automation on the agricultural sector. These innovations pave the way for smarter, more efficient operations, benefiting businesses and the environment alike.
