Turning Grain Dust to Gold
Presented by: Ann Crowley
Almost everything that is made
is weighed
Grain Industry Solutions
• Grain fields in eastern Illinois
and Wisconsin stretch as far as
the horizon in all directions.
• Towering clusters of b...
Fertilizer
Belt Scale
Grain Testing Grain
Balances Truck Scales
Hopper Scales
Grain for Feed,
Small lots, Seeds
RailRoad T...
Fertilizer
Belt Scales
• Belt Scales are a solution to load barge
containers and trucks
• A traffic jam of awaiting truckers
monopolized the near...
Grain
Truck Scales
Hopper Scales/920i FlexWeigh
Railroad Track Scales
Scales
Intercom Systems
Automated Vehicle Ticketing
• Improve safety
• Reduce labor costs
• Improve traffic flow
• Minimize “in-yard” times
• Minimize transaction errors
• Ma...
Truck Scale
with Traffic Light/Printer Kiosk
• In confined spaces like elevators and dryers,
ignition sources are always present.
• For years, grain terminal operators...
• Of all types of dust explosions, those associated
with grain dust are the most common and the
most dangerous.
• Any time...
• Even outdoors, grain dust creates
serious air pollution.
• When fleets of hopper-bottom semi-trailers are
unloading 1,20...
• Dust control is also a concern
because the area around
grain-handling facilities must meet
air-quality standards mandate...
• Many confinement systems directly contact
weigh hoppers, truck scales, conveyor scales,
and bagging scales.
• This conta...
Dump-Through Grating
• Cream City Scale LLC, (Rice Lake dealer)
wanted to integrate the Lowry
Manufacturing Company dust-collection
system with...
• Call it a ‗sock.‘It‘s a mesh lining that fits above
the hopper and below the scale.‖ The ingenious
part is the way the s...
• The sock fits like a glove.
• The interface of the sock to the hopper is
airtight, capturing grain dust along the entire...
• At the Gensler Grain Farm operation
near Rochelle, Illinois, efficiency is a top
concern.
• For farmers working overtime...
• Customer reports that the combination of
the SURVIVOR® OTR single-pit grain-
dump truck scale and Lowry dust-
collection...
• Jim also realized another advantage with
this system.
• He installed overhead bins to fill shipping
containers on the tr...
Overload System – Giant Checkweigher
• Advantage- ―With this overload system
design, drivers can drop excess weight
loaded...
• Jim Gensler agrees, ―When we‘re loading
containers for ships, they have to be exact, or
they will be rejected—there is n...
• S&S Grain Farm near Madison,
Wisconsin, has a gleaming new
grain facility with a dual-dump
SURVIVOR OTR truck scale,
ins...
• Proprietor, reports, ―It‘s smooth. We just pull on,
go in the scale room, punch a ticket, come out,
and open everything ...
• ―We‘ve hauled over a 1000 loads over it.
• We can leave here at 79,980 [pounds] not
counting a driver, go to the DOT sca...
Truck Scale Automated System
Automated System Drawing
Vehicle
ID KioskTraffic
Light
Printer
Kiosk
• Lay out your application
• Dream your solution
• We can help solve the issues!
• Save time
–Save money
•Be efficient
Env...
• Rice Lake‘s PL Series is available in several
platform sizes including 12'6, 15', and 18' to
provide maximum flexibility...
• Advantages of a modular scale over a
conventional pit style railway track scale
–Cost of the scales and the cost of the
...
–One set of trucks for each rail car would be
positioned on each platform, and the two
individual weights are automaticall...
The PL Series has also been designed to the
exacting standards of AAR, AREMA, Cooper
E-80, and are NTEP approved.
• Custom...
• Standard Features
–80,000 lb axle capacity
–320,000 lb full scale
capacity
–40,000 lb rail section
capacity
–115RE or 13...
• Full Draft Package Includes: (8) 5 ft 10 in rail
sections
• DoubleDraft Package Includes: (4) 5 ft 10 in
rail sections
•...
Grain for Feed, Small lots, Seeds
SuperSacks, Feed Ingredients
Floor Scales, Load Cells, 920 Systems,
Checkweighers, Sarto...
Hopper Scales
Equipment used
SuperSack
920i FlexWeigh
Bulkweighing Fillers (NTEP Approved)
107 Bulk Shipping
Repeatedly fills and discharges a
measured hopper un...
TradeRoute
Micro-Ingredient
Balances or Sartorius-Intec
What is Micro Ingredient Weighing?
• Any industry that
requires a blend of
powdered ingredients,
with any combination
of m...
What is Micro Ingredient Weighing?
• Any industry that
requires a blend of
powdered ingredients,
with any combination
of m...
Industry
Micro systems:
• Ingredients can be added
by hand, vibratory feeder,
and bulk bag, etc…
• Ingredients are either ...
Application Example
Equipment used:
• Rice Lake 920i (no A/D)
• Sartorius-Intec
1000 lb x 0.2 lb
(50,000 divisions)
• A&D ...
Application
• Micro ingredients as little as 0.1 g
are precision-weighed before adding
to batches weighing 1,000 lb
• The ...
Operation
If the target for the ingredient is 550 grams:
• The operator places an empty pan on the balance
and zeroes the ...
Operation
• Prompts: Is Recipe correct?
Operator presses YES or NO softkey
• Prompts: Enter/Scan ingredient
• 920i display...
Operation
• Operator will place a partial
or full barrel on floor scale
• Prompts: ―Enter/Scan Lot‖
Operator scans barcode...
Operation
• Operator dumps the product,
puts the empty barrel back on the scale
• Presses the Continue softkey to store
th...
Balance
• Operator places empty
pan on the balance and
presses zero
• Operator adds product
to the pan
• Prompts:
―Enter/S...
Lot Complete
When all the containers for the current lot
are used up…
• Operator presses the
Lot Complete softkey
• The to...
Lot Complete
• The 920i will display the next lot if there
are more for that ingredient
and go to Pick a Scale
• OR start ...
Ingredient Complete
• When the operator is satisfied with the
target vs. actual weight and/or all the lots
have been weigh...
Grain Testing
Balances
• Commercial dockage testing equipment
determines the percentage of impurities
(dockage) in various grain types.
• This eq...
• For smaller operations, dockage testing can be
performed manually using an FGIS approved
balance and sieves.
• Rice Lake...
• With a resolution of 4200 x 0.1 grams, the TP-
4200NT is well suited for dockage testing needs.
An RS-232 interface also...
• Enable the percentage function in
order to toggle between percentage and
grams. To clear previous data, hold
and release...
• Place dockage particles on balance and obtain
necessary values by toggling between
percentage and weight in grams.
• Wei...
End Products
Scales are not all!
Control Access
• Anheuser-Busch oldest
brewery is updated with
920 controller to replace
the obsolete and failing
micro-pr...
• Today, the furnaces are fed by four 920i
indicators programmed to batch coal at exact
tonnage and speed.
• The 920i rece...
• ―The 920i makes it easier to diagnose a problem,‖ said
powerhouse electrician.
• ―An alarm stops the process.
I can come...
Going Global
• 2600 distributors
• 80 Countries
• 22 Regional and national
sales directors
• Custom application, special
p...
Our Vision:
To be the best by every measure
Turning Grain Dust to Gold
Get the most out of your weighing or automation system!
Thank you
Contact information:
Ann Crowley
715 234 9171
acrowley@ricelake.com
Turning grain dust into gold
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Turning grain dust into gold

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Ann Crowley, Product Manager, Rice Lake Weighing Systems

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Turning grain dust into gold

  1. 1. Turning Grain Dust to Gold Presented by: Ann Crowley
  2. 2. Almost everything that is made is weighed Grain Industry Solutions
  3. 3. • Grain fields in eastern Illinois and Wisconsin stretch as far as the horizon in all directions. • Towering clusters of bins and elevators pinpoint the super- sized grain facilities at rail stops and small towns. • All is quiet—until harvest when the dust hits the wind. Grain Industry
  4. 4. Fertilizer Belt Scale Grain Testing Grain Balances Truck Scales Hopper Scales Grain for Feed, Small lots, Seeds RailRoad Track SuperSacks; Feed Ingredients Floor Scales, Load Cells CheckWeighers Sartorius-Intec, Balances
  5. 5. Fertilizer Belt Scales
  6. 6. • Belt Scales are a solution to load barge containers and trucks • A traffic jam of awaiting truckers monopolized the nearby service road; each eagerly inching their way toward the facility‘s entrance when the first in line was allowed to enter. • The busy terminal was utilizing a wheel loader to dump ammonium nitrate fertilizer through a floor grate, landing on a high-speed belt. Fertilizer
  7. 7. Grain Truck Scales Hopper Scales/920i FlexWeigh Railroad Track Scales
  8. 8. Scales
  9. 9. Intercom Systems Automated Vehicle Ticketing
  10. 10. • Improve safety • Reduce labor costs • Improve traffic flow • Minimize “in-yard” times • Minimize transaction errors • Maximize transaction count • Attract more drivers to a more efficient system Benefits Automated Vehicle Ticketing
  11. 11. Truck Scale with Traffic Light/Printer Kiosk
  12. 12. • In confined spaces like elevators and dryers, ignition sources are always present. • For years, grain terminal operators have invested in safety equipment and training to protect their personnel and property from combustion caused by flying fibers or ―flyings,‖ more commonly known as dust. Special Truck Scale Enhancement
  13. 13. • Of all types of dust explosions, those associated with grain dust are the most common and the most dangerous. • Any time grain is moved, processed, or stored, potentially combustible dust is generated and suspended in the air. Grain Dust
  14. 14. • Even outdoors, grain dust creates serious air pollution. • When fleets of hopper-bottom semi-trailers are unloading 1,200 bushels of grain every 11 minutes, day and night, clouds of dust can envelop the scale house and equipment and coat drivers‘throats. Grain Dust
  15. 15. • Dust control is also a concern because the area around grain-handling facilities must meet air-quality standards mandated by state and federal guidelines. • One of the issues encountered when confining dust in grain-handling applications is the effect confinement devices can have on weighing equipment. Grain Dust
  16. 16. • Many confinement systems directly contact weigh hoppers, truck scales, conveyor scales, and bagging scales. • This contact can increase potential errors with weighing-system accuracy if implemented improperly. Confinement Systems
  17. 17. Dump-Through Grating
  18. 18. • Cream City Scale LLC, (Rice Lake dealer) wanted to integrate the Lowry Manufacturing Company dust-collection system with Rice Lake SURVIVOR® grain-dump scales. • The Lowry system is inserted into the underground pit. • It pulls the proper volume of air from the pit to capture particles and return them to the grain stream. Dust Collection System/Truck Scale
  19. 19. • Call it a ‗sock.‘It‘s a mesh lining that fits above the hopper and below the scale.‖ The ingenious part is the way the sock is attached to the scale. • ―There is enough play so the load cells can be quickly accessed, and the sock won‘t affect the accuracy of the scale.‖ • Before the idea developed, scale techs attached the two systems in a way that made weighing components like load cells inaccessible—unless separated. Sock!
  20. 20. • The sock fits like a glove. • The interface of the sock to the hopper is airtight, capturing grain dust along the entire stream from hopper to pit. • The sock also prevents fugitive dust from building up on bearings, motors, and other peripheral equipment near the grain-handling system. • Cleaner, safer, more efficient. Grain Sock
  21. 21. • At the Gensler Grain Farm operation near Rochelle, Illinois, efficiency is a top concern. • For farmers working overtime to bring in their crops, safer and more expedient unloading of corn, soybeans, and other products represents a significant savings in time, equipment, and expense. Gensler Grain Farm
  22. 22. • Customer reports that the combination of the SURVIVOR® OTR single-pit grain- dump truck scale and Lowry dust- collection equipment has enabled him to operate with one less semi-truck and hire one less driver each season. • Drivers can fully open the gates on their trailers, and the system takes the grain away as fast as they can unload it. Grain-Dump Truck Scale
  23. 23. • Jim also realized another advantage with this system. • He installed overhead bins to fill shipping containers on the truck while the truck is on the scale. • Properly loading the containers is essential because freight companies will not accept overloaded containers. Overhead bins - enhancement
  24. 24. Overload System – Giant Checkweigher • Advantage- ―With this overload system design, drivers can drop excess weight loaded into the container back into the grain dump without leaving the scale. • Can you imagine the time that saves? • Instead of leaving the scale to dump the excess and returning to the scale to be re- weighed, they can stay on the scale in their cab, re-weigh, and go. • The SURVIVOR is their giant checkweigher!‖
  25. 25. • Jim Gensler agrees, ―When we‘re loading containers for ships, they have to be exact, or they will be rejected—there is no wiggle room.‖ No wiggle room!
  26. 26. • S&S Grain Farm near Madison, Wisconsin, has a gleaming new grain facility with a dual-dump SURVIVOR OTR truck scale, installed by Cream City Scale. • With two 6- by 7-foot openings, each pit is lined with finely tailored socks, thanks to this innovation. Dual Dump Truck Scale
  27. 27. • Proprietor, reports, ―It‘s smooth. We just pull on, go in the scale room, punch a ticket, come out, and open everything up. • We can unload 8,000 bushels an hour. • It takes 9 to 11 minutes from the time we punch in to the time we punch the scale out to run 1,200 bushels off a truck.‖ Customer Report
  28. 28. • ―We‘ve hauled over a 1000 loads over it. • We can leave here at 79,980 [pounds] not counting a driver, go to the DOT scale, and be right on. • We do load right at 80,000, so it‘s nice to know for sure. • You don‘t have to guess.‖ Testimonial
  29. 29. Truck Scale Automated System
  30. 30. Automated System Drawing Vehicle ID KioskTraffic Light Printer Kiosk
  31. 31. • Lay out your application • Dream your solution • We can help solve the issues! • Save time –Save money •Be efficient Envision your Application
  32. 32. • Rice Lake‘s PL Series is available in several platform sizes including 12'6, 15', and 18' to provide maximum flexibility in rail car weighing applications. • PL Series rail scales are available in Single, Single/Single, Single/Double, Double, and Double/Double module configurations. Railroad Track Scales
  33. 33. • Advantages of a modular scale over a conventional pit style railway track scale –Cost of the scales and the cost of the foundation construction are generally much less than a pit style scale. –Overall installation time is also significantly reduced when compared to a pit style design. Railroad Track Scale
  34. 34. –One set of trucks for each rail car would be positioned on each platform, and the two individual weights are automatically calculated to obtain a legal for trade Gross vehicle weight. –Rail cars may be weighed un-coupled at both ends or coupled at one end. Railroad
  35. 35. The PL Series has also been designed to the exacting standards of AAR, AREMA, Cooper E-80, and are NTEP approved. • Custom designs and platform configurations are available to meet the most demanding Railroad Track
  36. 36. • Standard Features –80,000 lb axle capacity –320,000 lb full scale capacity –40,000 lb rail section capacity –115RE or 132RE rail sections –5 ft 10 in rail sections, pre- drilled for joint bars RailBoss
  37. 37. • Full Draft Package Includes: (8) 5 ft 10 in rail sections • DoubleDraft Package Includes: (4) 5 ft 10 in rail sections • NOTE: RailBoss will not operate without the 920i indicator and RailBoss software • Options and Accessories –Custom rail sizes –920i indicator with RailBoss software for full draft or double draft applications RailBoss
  38. 38. Grain for Feed, Small lots, Seeds SuperSacks, Feed Ingredients Floor Scales, Load Cells, 920 Systems, Checkweighers, Sartorius-Intec, Balances
  39. 39. Hopper Scales
  40. 40. Equipment used
  41. 41. SuperSack
  42. 42. 920i FlexWeigh Bulkweighing Fillers (NTEP Approved) 107 Bulk Shipping Repeatedly fills and discharges a measured hopper until a specified target weight has been reached. 108 Bulk Receiving Repeatedly fills and dispenses a measured hopper until all product is received, then total. 109 Bulk Shipping or Receiving Toggle between bulk-shipping and bulk- receiving modes.
  43. 43. TradeRoute
  44. 44. Micro-Ingredient Balances or Sartorius-Intec
  45. 45. What is Micro Ingredient Weighing? • Any industry that requires a blend of powdered ingredients, with any combination of major, minor, or micro feeding and weighing devices to get the job done
  46. 46. What is Micro Ingredient Weighing? • Any industry that requires a blend of powdered ingredients, with any combination of major, minor, or micro feeding and weighing devices to get the job done
  47. 47. Industry Micro systems: • Ingredients can be added by hand, vibratory feeder, and bulk bag, etc… • Ingredients are either added manually by an operator or automatically generated with batch controller logic
  48. 48. Application Example Equipment used: • Rice Lake 920i (no A/D) • Sartorius-Intec 1000 lb x 0.2 lb (50,000 divisions) • A&D GP-12K 1200 g x 0.1 g (12,000 divisions)
  49. 49. Application • Micro ingredients as little as 0.1 g are precision-weighed before adding to batches weighing 1,000 lb • The recipe consists of several ingredients (up to 10) and each ingredient may have multiple lots • Maximum lots per ingredient is three
  50. 50. Operation If the target for the ingredient is 550 grams: • The operator places an empty pan on the balance and zeroes the scale • The operator presses the Start/Batch softkey • Enter Clock ID (operator ID – stored in Operator database), press Enter • Display shows recipe, each ingredient and lot on its own line
  51. 51. Operation • Prompts: Is Recipe correct? Operator presses YES or NO softkey • Prompts: Enter/Scan ingredient • 920i displays 5 softkeys – Floor scale – Balance – Lot Complete – Ingredient Complete – Cancel
  52. 52. Operation • Operator will place a partial or full barrel on floor scale • Prompts: ―Enter/Scan Lot‖ Operator scans barcode with the lot number or key in on front panel • Gross weight from scale is stored • Prompts: Dump Container and Press ‗Continue‘
  53. 53. Operation • Operator dumps the product, puts the empty barrel back on the scale • Presses the Continue softkey to store the tare weight from floor scale • The net weight is calculated and subtracted from the total
  54. 54. Balance • Operator places empty pan on the balance and presses zero • Operator adds product to the pan • Prompts: ―Enter/Scan Lot‖ • Gross weight from balance stored as the net weight and subtracted from the target
  55. 55. Lot Complete When all the containers for the current lot are used up… • Operator presses the Lot Complete softkey • The total net weight for that lot will be stored
  56. 56. Lot Complete • The 920i will display the next lot if there are more for that ingredient and go to Pick a Scale • OR start over at Enter/Scan Ingredient if there are no more lots for that ingredient but there ARE more ingredients left in the recipe database
  57. 57. Ingredient Complete • When the operator is satisfied with the target vs. actual weight and/or all the lots have been weighed, press the Ingred Complete softkey • The 920i will start over at Enter/Scan Ingredient if there are more ingredients left in the recipe database • If not it will display Recipe Complete
  58. 58. Grain Testing Balances
  59. 59. • Commercial dockage testing equipment determines the percentage of impurities (dockage) in various grain types. • This equipment can be a significant investment for smaller businesses. • What‘s more, to legally classify grain, dockage testing equipment must also be NTEP Class II and FGIS approved. Balances
  60. 60. • For smaller operations, dockage testing can be performed manually using an FGIS approved balance and sieves. • Rice Lake‘s TP-4200NT balance is not only Legal-for-Trade, but also one of the few balances one the market to offer FGIS approval. Solution
  61. 61. • With a resolution of 4200 x 0.1 grams, the TP- 4200NT is well suited for dockage testing needs. An RS-232 interface also lets you send results directly to a printer, for professional and accurate record keeping. • Convenient size and portability are just a few more reasons the TP-4200NT is an ideal low- cost alternative to commercially manufactured dockage testing equipment. Solution
  62. 62. • Enable the percentage function in order to toggle between percentage and grams. To clear previous data, hold and release the function key. • Place your complete sample on the balance to register 100%. • Process your sample using the appropriate sieves. Using the TP-4200NT to sort & classify
  63. 63. • Place dockage particles on balance and obtain necessary values by toggling between percentage and weight in grams. • Weigh remainder of original sample to obtain all necessary data. Send your results to an optional printer. Using the TP-4200NT to sort & classify
  64. 64. End Products Scales are not all!
  65. 65. Control Access • Anheuser-Busch oldest brewery is updated with 920 controller to replace the obsolete and failing micro-processing equipment. • Special programmed 920i® HMI controllers were installed and running in a couple weeks.
  66. 66. • Today, the furnaces are fed by four 920i indicators programmed to batch coal at exact tonnage and speed. • The 920i receives instructions and reports data on a control network with an Ethernet IP, DeviceNet or Remote I/O option card. Beer facility
  67. 67. • ―The 920i makes it easier to diagnose a problem,‖ said powerhouse electrician. • ―An alarm stops the process. I can come out here and read the screen. • It will tell me where the problem is in the system, such as the inlet or the outflow. • It will tell me how long the belt runs to fill the 250-pound hopper, or if the belt conveyor fails to fill the hopper. • The 920i indicators are reliable and they‘re very user-friendly.‖ Belt Scale to Hopper System
  68. 68. Going Global • 2600 distributors • 80 Countries • 22 Regional and national sales directors • Custom application, special product or software enhancement – we find the solution. • Locations: – Rice Lake, Wisconsin – Jasper,Alabama – Fernley, Nevada – Heteren, The Netherlands – MSI - Seattle, WA – Condec - Newtown, CT • Joint Venture: – India
  69. 69. Our Vision: To be the best by every measure
  70. 70. Turning Grain Dust to Gold Get the most out of your weighing or automation system!
  71. 71. Thank you Contact information: Ann Crowley 715 234 9171 acrowley@ricelake.com

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