Denver Stockfeeds provides dairy feed and stock feed in the Manawatu and throughout New Zealand. It was established in 1998 on a family farm before moving into an old flour mill in Palmerston North in 2001.
The control system in use at the feedmill was nearing the end of its life. The site had multiple control systems with little documentation and support. This presented an increasing risk to the plant’s production, product quality and traceability.
Minimising the downtime of the plant was the most important factor in changing over the control system. An approach was adopted that minimised interruptions to plant production. Due to the complexity of the plant, which included separate ruminant and mono-gastric lines with shared devices, and the importance of continued production, the changeover to the new control system was based on several shutdowns over 18 months.
Gordyn & Palmer project managed the upgrade providing automation and electrical support and liaised with management, production schedulers and local contractors.
The latest state of the art Genius Feedmill control system, produced locally by Gordyn & Palmer, was installed at the mill. The system controls feed production from the raw material intake to the out-loading of finished product. It includes highly accurate batch weighing and automatic press control.
The system is Ethernet based and operates on a standard PC making the need for specialised equipment obsolete. It handles all weighing and mixing tasks as well as recipe input, batch sequencing, destination control and reporting.
The hardware used to build the Genius system includes the latest developments in computer and process control technology. This structure enabled all communication security to be handled using the same security technologies with which their IT departments used.
The site control system is now fully integrated and provides security with weighing accuracy, comprehensive reporting, full product traceability and 24 hours/7 days a week support.