MEI Automated Fertilizer Facility Helps Nutrien Ag Solutions in Tipton, IN Resume Growth with Increased Throughput and Efficiency
What They Needed
After years of record-setting growth, the Nutrien Ag Solutions location in Acadia reached a critical point. Taking on new business was no longer sustainable without risking the level of responsiveness their customers had come to expect.
“We had maxed out” explained Nutrien Ag Solutions Location Manager Todd Harris. “I felt like if we continued to grow at the pace we had, we were going to lose the customer service that we had become known for. There were a lot of sleepless nights.”
At this point, Nutrien’s Project X team approached Harris with a proposal to construct a new, larger, and more centralized facility.
What We Designed
Murray Equipment (MEI) was chosen as a one-stop-shop provider for all the liquid fertilizer operations. MEI provided the prefabricated facility and liquid handling equipment; railcar and truck offloading systems; premix, repackaging, and loadout systems; motor starter, valve, and system controls; and ICS ControlPro plant software.
The facility features 2 manned loadout bays, 1 unattended bay, a dual repackaging center, both rail and truck offloading, and a warehouse/storage facility. The facility features 2 separate systems for beans and corn as well as mini-bulks attached to dedicated pumps and meters to prevent cross-contamination.
This state-of-the-art facility is fully automated with MEI’s ICS 480 system and ICS ControlPro which integrates directly with the Nutrien system.
“I’m not a computer guy. I was nervous about the computer side,” Harris said. “They made it very easy to learn. We spent a day and a half training in Fort Wayne, and after installation, they gave us another half day. The next morning, we were already loading product on our own.”
Benefits Achieved
The new facility quickly delivered measurable improvements in efficiency and visibility. Semis are being loaded 20-30min faster. Instead of a single bay, they now have 3 – 2 manned and 1 unattended. Automation through ICS ControlPro has streamlined daily operations.
“I can see everything that’s going on now—what we did the day before, who got what, and what we need to do next,” Harris shared. “It’s automatically sent to me every morning. I don’t have to track down paperwork. It’s right there at my fingertips.”
There are other operational benefits. Bringing in fertilizer by truck used to be a week-long process. Now with the railcar offloading, it can be reduced to 3 hours.
“This facility has now made me realize it’s time to grow again.” Todd Harris enthused. “The efficiencies and the speed have doubled. It’s just made the work environment all around better here for us.”
FACILITY PHOTO GALLERY
exterior
Nutrien Ag Solution’s Arcadia Tipton location is now larger and more centrally located to serve the area.
interior
Murray Equipment, Inc. was a one-stop-shop provider of the facility equipment, liquid handling system and components, ICS Controls, and ICS ControlPro plant automation.
attended bays
The facility features 2 fully automated loadout bays. Nutrien Ag can load trucks in half the time, now with 3 times the bays.
unattended bay
A 3rd unattended loadout bay allows for round-the-clock customer service without additional staffing requirements.
controls
The new facility is fully automated with ICS ControlPro and ICS 480. ICS ControlPro manages customer tickets and batches, the 24-7 unattended loadout bay, and sending/receiving information from Nutrien’s software.
ICS 480
The ICS 480 offers a touch screen manual switch HMI panel.
premix
The site features MEI turnkey solutions such as this Premix Tank System.
catwalk
MEI supplied prefabricated catwalks and stairs designed to not only improve facility safety, but also to promote a better work environment.
pumpandmeterstands
MEI’s Turnkey Pump & Meter Stands automatically pull chemistry and/or micronutrients from mini-bulk tanks to add to the system blend.
repack
The facility includes a repackaging area that is also automated through MEI’s ICS 480.
Todd Harris
Todd Harris, Arcadia Tipton Location Manager
Motor Starter Panels
Murray Equipment provided the motor starter panels which are manufactured in Indiana alongside its other ICS control Panel.
Central Storage
Nutrien greatly increased its storage capacity. Thanks to the new centralized location, this facility can also store and move product to other locations as needed.
Central Storage
Nutrien greatly increased its storage capacity. Thanks to the new centralized location, this facility can also store and move product to other locations as needed.
Dike Stairs
MEI manufactured and supplied all the prefabricated safety equipment, including the dike stairs.
Dike Stairs
MEI manufactured and supplied all the prefabricated safety equipment, including the dike stairs.
Offloading
The 3rd Unattended Bay also doubles up as a bay for offloading trucks.
ICS ControlPro
ICS ControlPro is the industry’s only NTEP approved software. It works seamlessly with the ICS 480 and Nutrien’s ERP system to create complete plant visibility.
Catwalk Stairs
By opting for stairs over ladders, Nutrien greatly increased plant safety while reducing employee strain.
TCS Meters
Known for their accuracy and robustness, the TCS 682 Positive Displacement Meters are manufactured in-house at Murray Equipment’s headquarters via its TCS division.
Mass Meters
The location features 2 high flow Mass Flow Meters. Nutrien opted to create separate systems for corn and beans to reduce the risk of cross-contamination.
Easy to Use
While not “computer people” by nature, Nutrien employees find the ICS controls to be intuitive and easy to operate.
UAN Tank
The 2 million gallon UAN tank is fed into the facility via two large pumps.
One Stop Shop
Beyond the standard liquid handling equipment, Murray Equipment supplied everything including the repackaging frames, tote racks, hoses, nozzles, pivoting hose arms, hose holders, down to the buckets and spill prevention equipment.
One Stop Shop
Beyond the standard liquid handling equipment, Murray Equipment supplied everything including the repackaging frames, tote racks, hoses, nozzles, pivoting hose arms, hose holders, down to the buckets and spill prevention equipment.
One Stop Shop
Beyond the standard liquid handling equipment, Murray Equipment supplied everything including the repackaging frames, tote racks, hoses, nozzles, pivoting hose arms, hose holders, down to the buckets and spill prevention equipment.
Aerial
Aerial photo of Nutrien Ag Solutions new Tipton/Arcadia Indiana Location
