CropLife Facilities Issue – GRAINCO FS, Inc. Mazon, IL

WHAT THEY NEEDED     

When a fire burned down the chemical shed at GRAINCO FS, Inc.’s Mazon, IL location, it presented an opportunity to fully automate the location and redesign the equipment from the ground up.

GRAINCO FS’s Mazon location specializes in producing hot loads in addition to straight chemical and fertilizer loads. They fill both their own vehicles and sprayers as well as customer tanks.

“We had a few simple product presets before,” explained Brian Mino, GRAINCO FS Operations Manager. “Now with full automation, we have a lot more product diversity.”

Speed and accuracy were at the forefront - producing the right blends in a timely manner. GRAINCO FSneeded an equipment and automation provider that would give them the flexibility to produce the multitude of blends required by their customers, accurately and quickly.

Having worked with Murray Equipment and used their ICS controls previously, the decision was easy for GRAINCO.

WHAT WE DESIGNED

The 18,000 square foot facility features 3 loadout bays – 2 bottom load and a 24/7 unattended loadout with top and bottom load, a mini-bulk filling station, 1 million gallon solution tank, 180,000 gallons of liquid fertilizer, and 65,000 gallons of bulk herbicide storage.

ICS ControlPro software connects with GRAINCO FS’s agronomy software bringing in ticket, formula, and material information. It also manages equipment and customer information for the unattended bay. The 2 attended bays are managed by ICS 240c touch screen control boxes. The unattended bay features a touch screen control box with full keyboard for equipment/driver verification.

“We get along great with ICS. The support is good. It’s easy to run,” expressed Mino.

BENEFITS ACHIVED

The Mazon, IL has become the location of choice for area growers. The speed, accuracy, and number of blends available are a big customer draw.

“We had guys that would get a load of chemicals and apply it themselves in the field,” Mino said.  “Now they come here and get hot loads for the ease, and because they can get in and out of here quickly.”

During the planting season, trucks used to be lined up outside nonstop. Now, traffic flows through the building much more smoothly resulting in happier customers and employees.

“It used to take 45 minutes to fill a semi. Now the semi is in and out in under 15 minutes,” shared Mino. “Also, before we could only load in 2 bays, but now we can load in 3.” 

FACILITY PHOTO GALLERY

exterior

Brian Mino, GRAINCO FS, Inc. Operations Manager

aerial

Production and loadout are controlled by ICS 240c with 2 expansions. The expansions are used to manage the large number of customer blends.

ICS ControlPro

Semis can be loaded in less than 15 minutes. Previously it would take more than 45 minutes.

Loadout Bays

MEI’s unparalleled understanding of both equipment and automation is behind this neat, convenient, and compact facility layout.

Safety

An automated tote repackaging area means the location can fill small totes in addition to large semi loads.

scales

All the equipment, plumbing, metering, and controls were engineered by Murray Equipment. The goal was to offer an extensive line of liquid fertilizers, chemicals, and hot loads.

Meters

GRAINCO FS’s new liquid fertilizer and crop chemical building is part of a larger multi-service location in Mazon, IL.

Automation

Production and loadout are controlled by ICS 240c with 2 expansions. The expansions are used to manage the large number of customer blends.

Skids

MEI’s unparalleled understanding of both equipment and automation is behind this neat, convenient, and compact facility layout.

Skids 2

The location features 3 loadout bays, 1.18 million gallons of liquid fertilizer, and 65,000 gallons herbicide.

Tanks

A conveniently located touch screen panel allows employees to quickly create accurate batches.

layout

The 3rd unattended bay is accessible 24/7. It is used by GRAINCO and area growers to transport product round the clock and offers both top and bottom loadout.

manager

All the equipment, plumbing, metering, and controls were engineered by Murray Equipment. The goal was to offer an extensive line of liquid fertilizers, chemicals, and hot loads.

valves

The facility features 2 bottom load attended bay that specialize in hot loads.

valves

The intuitive ICS 24-7-8 Controls vertify drivers and equipment. The same ICS Control Pro software that runs the facility is used in the touch screen control panel for seamless operation.