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AutoMill — a product of Kairos

Projects

Feed mills running on AutoMill

How AutoMill automated plants for Triple V, ALZU, CIM and Nutri Feeds — the scope, the results, and what the operators said.

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Real plants, real numbers

Five plants automated — here's what changed on the floor.

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Plants automated

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Tons / month (Bloemfontein)

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Operator in the control room

Triple V Animal Feed — AutoMill installation

Triple V Animal Feed

Completed Nov 2016

Scope

  • Security
  • Weighbridge
  • Intakes, bunkers & raw-material management
  • Batching control
  • Recipe management
  • Production scheduler & forecast
  • Traceability
  • Outloading (per compartment)
  • Stock management
  • Reporting & integration
  • Quality
“Customized to our specific needs”
“Excellent after sales support – they do not leave you alone”
“The Automill system showed us many gaps in our processes”
“Improved Stock Control”
Kobus du Toit — General Manager, Triple V Feeds
ALZU Feeds — AutoMill installation

ALZU Feeds

Completed Jun 2017

Scope

  • Intakes
  • Batching control
  • Recipe management
  • Production scheduler & forecast
  • Hand additions
  • Reporting & integration
“A well planned and professionally rolled out project”
“Kairos staff are skilled and well equipped to complete tasks at hand”
Kelly Cornelius — ALZU
CIM Feeds — AutoMill installation

CIM Feeds

Completed Oct 2016

Scope

  • New ruminant plant automation
  • Intakes
  • Batching control
  • Bunkers & raw-material management
  • Recipe management
  • Production scheduler & forecast
  • Hand additions
  • Traceability
  • Outloading
  • Packing
  • Reporting & integration
Nutri Feeds Viljoenskroon — AutoMill installation

Nutri Feeds Viljoenskroon

Goals

  • Improve product quality and consistency
  • Batching accuracy to group standards
  • Reduce manual labour, error and contamination
  • Renew MCC, electrical hardware and instrumentation

Results

  • ▸Weighbridge intakes through to production, pelleting and outloading were automated, and are now run by one person in a central control room.
  • ▸Removing manual control brought much better accuracy, better stock management and consistent quality.
  • ▸Nutri Feeds has since added a third pelleting line to meet demand, with mixing capacity increased to match.
Nutri Feeds Bloemfontein — AutoMill installation

Nutri Feeds Bloemfontein

Goals

  • Improve product quality and consistency
  • Accuracy to group standards
  • Reduce manual labour and human error
  • Lift throughput from ~6 000 to 8 000 tons/month

Results

  • ▸From intakes through production, pelleting and outloading, every process was automated and is now run by one person in a central control room.
  • ▸In the first six months the plant set a new record of 9 000 tons/month, then reached 10 000 tons/month over the following six months by acting on downtime data — while holding the quality they expect.
“I do believe we have much better quality now due to the accuracy we get, as well as much higher throughputs than before. That means lower costs per ton to produce and makes us more competitive in the market. From a reporting side, we can see everything that goes on in our plant and fix problems much faster thanks to better visibility.”
Johan van Zyl — National Operations Manager, Nutri Feeds

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