ICT in farming and storage

At all levels on the farm, technology is used to improve efficiency, monitoring and reliability. For example:

Precision farming

Traditionally, farmers applied fertilisers evenly across the field. However, the nutrients required by the soil are likely to vary across the field. Precision farming uses technology to accurately monitor soil nutrient levels and apply fertilisers where they are needed, thus tailoring the inputs (e.g. fertilisers and pesticides) to specific crop needs. Applied effectively it not only increases profitability by increasing yields and reducing inputs, but benefits the environment.

Global positioning systems (GPS)

GPS fitted to tractors and combine harvesters allow farmers to map each individual field. Combined with nutrient mapping, the farmer can assess the type of soil in the field and adjust growing techniques and use of fertilisers and pesticides to maximise wheat yield while also protecting the environment. Farmers are aware of the environmental impact of fertiliser application – not only because they are concerned about polluting the environment but also because fertilisers are an expensive part of crop production.

Like all businesses, farms have to balance the potential benefits of technology against the cost, and technology should be used in conjunction with the farmer's husbandry skills. For example, a farmer would need to have a reasonable area of land before considering investing in expensive equipment needed to take advantage of precision farming and global positioning systems.

Crop scanning

Crop scanning by remote sensing can be used to determine how much application of nitrogen is needed. Suitable equipment includes tractor-mounted sensors, airborne scanners and cameras. Experiments have shown that remote sensing can improve efficiency by allowing farmers to vary the amount of nitrogen they apply to different parts of a field, depending on the planting date.

Grain storage/monitoring quality

The moisture, temperature and quality of the grain can be monitored and controlled using sensors and other ICT equipment. These can react to changes in humidity and temperature to keep the grain at the right constant state.

Weighing

A weighbridge weighs a farmer's load of grain. While the grain is being weighed, a number of other checks can also be made using business systems, laboratory quality control and stock management systems across one or many sites. Data can be transmitted by LAN or WAN (Local or Wide Area Networks). In a sophisticated system, one operator can operate several weighbridges, while the drivers remain in their vehicles; the documentation about the load is transferred to the operator via a pneumatic document dispatch system. The operator logs the details into the computer and the load is checked against the contract. If the details are validated, a remotely operated sampling spear takes a sample of the grain, which is sent to the laboratory for quality tests. If these tests are satisfactory, the driver can unload the grain. Having linked information about grain loads saves manpower and time and improves accuracy, all of which benefits the flour and grain industry. Fully integrated systems are not universal, but most millers and wheat merchants use some form of weighbridge automation.

ICT in milling

Monitoring wheat moisture content

Before wheat is milled, it is 'conditioned' with water to ensure a consistent moisture content and in ideal condition for milling. One of the most widespread process control (see below) applications in the mill is the automatic control of wheat dampening and conditioning, designed to give wheat a uniform moisture content. Systems are also available to control the 'lying time' of the grain: a conditioning bin can be maintained at a constant level by matching the rate of damping to the rate of use of the grain by the mill.

Checking flour stream quality

Near Infra-Red (NIR) analysis can be used on-line to measure the protein and moisture content of the flour streams during milling. The instruments can be used as part of a control loop (see below). There are two systems, the NIROS and the MYRA; in both, the frequency of analysis can be adjusted, and the data can be presented in complete form or with a number of results averaged.

Adjusting the rollers

ICT can adjust the roller settings remotely and automatically uses process control (see below), keeping the balance of the flour streams correct. The roller floor is the main area of milling adjustment once the grist is on the mill; any corrective action required is generally applied here. The mill computer scans and memorises the roll settings for each grist. The previous settings for any grist can then be reapplied by the computer. This is expensive but enables roll settings to be changed rapidly at any time without supervision. This ensures the different flour streams are correctly balanced.

Packing the flour

Programme Logic Controllers (PLC, see below) are used for 'carousel' packing, where over 600 bags of flour may be packed per hour on an automatic carousel. Computer-controlled bag filling means exactly the right amount of flour is added to the bag. This also saves money because bags are not over-filled.

The most common level of automation for flour packing is a one-person operation in which paper sacks are manually fitted to the carousel and the rest of the process is automatic. The bags are either filled to gross weight by a load cell or to net weight by a loss-in-weight feeder. Closing, stitching and labelling are carried out using elementary process control.

Palletisation

ICT is used to pack the bags as efficiently and neatly as possible onto larger trays (pallets). Bag dimensions and weight, plus details of how bags are arranged on the pallets, can be programmed into a microprocessor. Pneumatic handling rams form the bags into square-sided palletised units.

Automated palletisation means the pallets are stacked safely, take up less space and look pleasing to a customer. You can also choose the best palletisation pattern for particular pack sizes, pack weights and pallet sizes. Cases and pallets can be uniquely identified with automated labels, detailing product and bar code information, enabling traceability by text or codes.

ICT in baking

Large bakeries use PLC to control a number of baking processes. For example, the press of a button can regulate the amount and type of flour to be used, the temperature of ovens and the cooling times.

PLC are often referred to as ‘chips’ and they are programmed by an external device using code. Each chip can receive a number of different commands and control a number of different systems. PLCs are mostly used to control the actions of machinery. Advantages of using PLCs include:

• Flexibility: programmes can be changed easily.
• Reliability: almost all PLCs can run simulation tests to verify programmes and performance.
• Ease: installing a PLC is straight-forward and individual printed circuit boards are easy to replace.

Engineers and bakers ensure that everything runs properly in the bakery, that there are no faults in the system and that the right ingredients are being used for the different breads.

ICT in retailing and marketing

Retailers and suppliers have linked computers to share order information and invoices using electronic data interchange (EDI). The internet is used to exchange a wide range of information, including sales figures and stock levels. Business to business e-commerce can help track special features such as promotions. The internet is also a powerful marketing tool, with many retailers offering online shopping.

Process control systems (PCS)

The term ‘process control’ in the flour and grain industry refers to using the rapid information-handling capacity of computers and microprocessors to carry out different functions in the grain chain, e.g. the milling process. There are many methods of automatic control, and individual methods or combinations of methods are used in process control. There are two main types of digital processors:

• Logic controllers: these evolved from relay systems and give almost limitless scope for process control by sequencing and interlocking motors etc. using individual programmes. The use of large-scale integration (LSI) allows delays and timers to be part of the controller rather than external.
• Loop controllers: these use a continuous path from a sensor through the controller or monitor to the process variable in question. There are two types: on/off loop controllers and time proportioning loop controllers. Their operation can be described as:
  • Proportional: a proportional loop controller makes a correction directly proportional to the error sensed.
  • Integrating: integrating units also gauge their correction action with reference to the degree or error.
  • Derivative (or differential): the derivative element relates to how long the error has lasted.
  The most common loop controllers are Proportional Integrating Derivative (PID). They combine all three features of operation.

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