Automation and Grain Processing

Grain processing benefits from automation and industrial wireless

The grain industry serves as an example of industrial process control, where standards are maintained at a constant rate for product delivery. Automation in grain processing provides both safety and efficiency by supporting the product delivery process. Historically, the grain production process has been hazardous, with industry workers subject to harsh conditions and potential risks associated with the grain, such as flammable grain dust. The transition from manual labor to automation has become the industry’s essential shift, with automation now a staple in harvesting, milling, and handling grain. The developers of automation components seek to mitigate production ineffectiveness and inventory miscalculations. Solids level transmitters, responsible for continuously monitoring the amount of grain in potentially hazardous environments, are a reliable replacement for employees at a silo’s peak.

Thanks to developments in technology, the implementation of sustainable automation does not need to come at the expense of company profit. A sole driver needs to control automation operations when dealing with grain handling, meaning that the number of employees put at risk via that stage in the process is substantially reduced. In order to keep track of inventory, automated management tracks not only the levels of grain inside silos but also where materials are located throughout the production facility. Grain sensors allow for the constant communication of how much grain is being moved through grain elevators and terminals. Instrumentation measures level, weight, and flow of solid grain while maintaining process protection.

Grain terminals allow for grain to be unloaded into hoppers, and then conveyors transfer those hoppers to the elevators. Cleaning drying, and blending machinery all employ automation, reducing the risks presented to employees. Truck and rail load-outs need to be close to target levels, because overloading or under-loading transport results in product loss. Preventing the loss of time and physical resources is a key element of automation. Radar transmitters cut through dust in silos to deliver reliable information back to the process operators. Ultrasonic instrumentation matches with point level technology to indicate when grain levels are high or low.

The handling and blending of raw materials can be monitored by solid flowmeters, with high accuracy still applicable in more compact spaces. A similar solid flowmeter ensures the accuracy of the flow rate and weight of solids measured in bulk, and can also be used in tandem with flow and weigh feeders to keep each individual load of grain consistently accurate. The applications of automation throughout the grain production process have evolved into a reliable means of reducing employee risk while ensuring accuracy and increasing throughput.

Grain operations cover large areas. A reliable, flexible, and cost saving way to establish the needed process control connections throughout the facility is via industrial wireless. Connections between measurement instruments and control units can be created across very long distances without the need to install conduit and cabling. Connections can be created quickly and reliably, with flexibility to increase throughput as more stations or sensors are needed. Equipment is suitable for general or hazardous locations. Contact an industrial wireless communications expert for help in developing connections on your project.

Wireless Communications for Industrial Automation Continues to Expand Because It Performs

Wireless communications capabilities for process control
extend beyond WiFi

Wireless connection between a sensor and control or monitoring station is not new anymore. Products have matured, familiarity with the technology is widespread. Certainly, there are still large swaths of industrial installations that do not utilize the technology. This can be for any number or reasons, but new industrial technology tends to follow a predictable course throughout its adoption. There will be innovators and early adopters that can justify higher risks with the prospect of great returns. Many industries and companies will wait until perceived technological difficulties with implementation are overcome and products become more mainstream and easy to apply. That is where industrial wireless is today. Assembling complete working systems is a straight forward operation. Costs are comparatively modest. It's easier to visualize a payback.

Let's review some of the benefits a wireless installation can bring.

• Safety: Wireless connections can reduce personnel exposure to hazardous environments or situations that previously required human intervention or a manual gauge or instrument reading.
• Easy Scale-up: Adding points on a network is generally a simple incremental process.
• Operational Advantage: When deployed to replace manual instrument or gauge readings, real time data for diagnostics and efficiency measurements are now available. Information that is more accurate, timely, and consistent will produce better results.
• Installation Savings: Installation of wireless connected assets has been reported to be up to 10 times less expensive than wired installation. The reduced space and planning for cables and conduit can make what were once complex and time consuming operations much quicker and easier.
• Mobility: Wireless technology allows for real time connections to mobile platforms. Whether within a plant, on the road, or on the high seas, there are wireless products that can make the connection.
• Distance: Don't just think WiFi, think radio, think satellite, think cellular. Connections can be established across very long distances using standard products from the industry.
• Conversion of Legacy Devices: Many existing in-place devices can have their wired connections replaced with a wireless version. This accommodates a staged transition from wired to wireless in facility.

Analynk Wireless manufactures a broad range of wireless communications equipment for industrial process control and automation. Share your wireless connection challenges and ideas with the experts at Analynk and start benefiting from the technology. It's not new anymore. It's mainstream.