Bulk handling sites must manage fluctuating needs, depending on when different agriculture products, such as wheat, barley, beans, and canola, are harvested in that country. These sites require lots of infrastructure and real estate to run operations, and require many people to keep these facilities running.
For optimal profitability, agricultural bulk handling sites should look for ways to automate processes throughout the agriculture supply chain.
Automating processes at bulk handling sites will maximize the efficiency of resources, both people and equipment. Bulk handling sites should invest in these tools:
1) Automated weighbridges (truck scales)
A typical weighbridge or truck scale at a bulk handling site requires lots of resouces: several people to man the station plus digital message signs, printers, sensors, readers, and traffic lights.
With InSight CM - Smart Scales, the truck weighing function at bulk handling sites becomes automated and weighbridges become unmanned, which frees up resources to use at other locations at the site. The weighing function is automated at each weighbridge station: when the incoming truck is weighed with its cargo, and after the truck dumps its cargo and is weighed empty. Using camera technology, trucks are led onto the scale using a smartphone app to direct the truck exactly where to go. Camera technology is used to verify the number of axles of the truck, and to determine if an axle and its tires are not positioned properly over the scale; instructions are then given to the driver to move forwards or backwards to get a proper reading.
With smartphones, sites can communicate to the driver through his smartphone during the weighing process. Confirmation messages are sent to the driver to alert him when it is time to proceed onto the weighbridge. If the driver proceeds too far, he is directed to move backwards. Eka’s software is more sophisticated than a contact solution that counts the number of tires putting pressure on the weighbridge, as Eka’s software also detects lifted axles, which is impossible with a contact solution.
Eka provides the smart scale software to automate weighbridges. Using smartphones to communicate with and track drivers via GPS, and camera technology to accurately get a reading of the number of axles and weight of a truck, the software eliminates the need for a lot of hardware that is otherwise required to run the weighbridge.
2) Automation control software
Automation control software provides a site operator with better insight into all operations across the site and the ability to track all movements. Sites run more efficiently with control software. Picture this: a driver departs the incoming weighbridge, then proceeds to where he was directed to deliver the product. The software verifies that the truck arrives at the correct discharge point, and via smartphone the driver is asked to confirm he is where he is supposed to be. Transaction information such as commodity and quality type is cross-referenced to avoid cross-contamination.
InSight CM - Site Automation Control software gives bulk handling operators the ability to manage site operations throughout their site, and provides real-time visibility of what’s on hand as well as scheduled upcoming orders to go out. With this type of real-time information, sites can better determine ways to cut costs in various areas. Managers and operators can log in from anywhere to see what commodities are stored where, what’s coming in, and what’s going out.
With Eka’s control software, equipment can be efficiently operated at the site, including belts, elevators, valves, and fans. The software saves costs by only powering equipment when it’s needed – sites no longer need to leave the belts running all day. Because of the integrated software modules, site operators know where all the delivery trucks are on-site, and the software will start and stop equipment as needed.
With Site Automation Control, sites can manage operational movements, shipment planning, and inventory information, including samples, moisture, and quality levels. Eka’s software provides visibility into all of the processes at a site; all of the information is integrated into one platform. And with multiple sites, the software allows site operators to see all sites from one location which maximizes traceability.
3) Automated sampling probes
Sites will benefit from automating the sampling process at truck scales and weighbridges (where the contents of the truck are tested to determine the type of commodity and the quality level of the commodity). Automated sampling probes can free up resources otherwise dedicated to the manual process of sampling.
Sites can use Eka's InSight CM - Smart Probes to replace the manual process of sampling. With Smart Probes, trucks arrive at the sampling probe area where multiple cameras are mounted in various positions to determine the truck’s configuration; for example, is there a tarp or metal bars on the top of the truck? Similar to a vacuum cleaner, the sampling probe takes multiple samples of just a few milliliters of the product from near the bottom of the truck. The samples are poured into a small cup where the contents are then evaluated by a sampling analyzer machine, and the grade is displayed based on the quality results of the product (protein, moisture, and screening).
Using Smart Probes, sampling stations run automatically, and require no manual intervention. Automated sampling is more accurate than the manual process, and frees up resources.
4) Mobile apps
Smartphones have become prevalent in our society. By taking advantage of the standard features of smartphones, such as GPS, sites can streamline their operations and move to a paperless process. With mobile apps, sites can make use of smartphones to communicate with drivers throughout the site.
With Eka’s platform, smartphones can be used for driver communication throughout the receival process to track delivery trucks and communicate with the drivers. The benefits are that operators know when trucks are coming to deliver products, and operators can eliminate a lot of on-site hardware and infrastructure previously used to direct trucks on-site.
With Eka’s platform, sites can keep in communication with drivers and track the progress of drivers as they move through the receival process at the site. Smartphones help keep the site operating smoothly, and they eliminate the need for paper tickets and receipts.
5) Bulk stock management software
Sites will benefit from anything that enables them to more efficiently manage inventory and track movement of stock throughout their sites. By automating tasks, sites will maximize resources and throughput.
Eka's InSight CM - Commodity Site Manager is a web based portal for tracking all transactions and provides complete visibility of all stock. Site operators can manage stock inventory and the movement of such stock between stations at a site and as stock is moved outbound from a site using a web interface.
This software allows staff to define quality parameters for stock and to raise orders for the movement of product, including billing. The transaction entry application manages the receival of this stock into the site and the movement out, capturing all required information in real-time. This gives decision makers the ability to monitor accounted stock across an entire enterprise from the palm of their hand, and if necessary, adjust and regrade the site stock levels. The web portal can even be customized with corporate logos, imagery, and colors.
6) Truck booking system
During non-peak seasons, sites can use an integrated booking system to schedule incoming trucks delivering products from the growers by assigning specific time slots to drivers. For example:
- One truck is scheduled to deliver at 8 AM
- Another truck is scheduled for 8:15 AM
- Another at 8:30 AM
- and so on…
This type of booking system can eliminate or lessen truck queuing times when entering the site. Because this system is more efficient, the site saves money, the growers would rather do business with that site than a less efficient site where queue times are longer, and the drivers are happier.
Eka's integrated truck booking system, InSight CM - Truck Booking, can be used to shorten queue times for incoming trucks. Suppliers can view what time slots are available in advance of shipment, and trucks coming from suppliers to the site to deliver product are assigned specific time slots. InSight CM - Truck Booking increases efficiency at the site, and helps maximize profits for site operators.
The Key to Efficiency - Automation
As agricultural production increases due to growing global population, bulk handling sites will need to look for ways to reduce costs and increase throughput. The smart bulk handling site of the future will leverage automation as a way of increasing efficiency. Specific tools that will be implemented include:
- Automated truck scales or weighbridges
- Control software to operate everything at a site or a network of sites
- Automated sampling probes
- Mobile apps to communicate with drivers at a site
- Bulk stock management software
- Truck booking system
With Eka’s platform, all of these technologies are integrated to work together. Site operators maximize their resources and gain an impressive ROI.
Eka's InSight CM platform provides bulk stock management, process management, task execution, and business intelligence for the bulk handling industry including grain facilities and port terminals for all types of commodities. With Eka’s bulk handling software platform, physical assets (machinery, storage locations, ports, etc.) operate at maximum efficiency in the storage or movement of physical bulk commodities — providing the most throughput for the least amount of downtime and cost.
