Plantwide Systems

Complete Plant Automation

Sterling Systems & Controls, Inc. offers complete customized plantwide systems and process control and automation system solutions for a wide range of industries. Examples: Food processing/manufacturing requires the control of a variety of different processes from start to finish; Feed is produced for nearly every domesticated animal, including Pet Food for our dogs and cats. Feed production is done in a Feed Mill. The term “Feed Mill” and the word “Feedmill” are used interchangeably. Sterling Systems can provide plantwide systems for the Feed Mill and Pet Food industries/facilities. Also, it offers automation and control for individual aspects of the manufacturing process such as in Feed Mill operations (examples shown below). In addition, Sterling Systems can provide fully integrated plantwide systems as turn-key by working with our partner network.

The Sterling Systems automated batching systems are at the heart of many industrial bulk solids processing facilities, and definitely for Feed Mill automation solutions. Our WebCentral software is the central nervous system of a plantwide system. It allows for the management of Ingredients, Formulas, Bin Assignments, Schedules and other data tables in a batching process as an example in a Feed Mill. In addition, you can view and print historical batching and process data reports. PLC-based control systems are constrained by limited PLC memory. They hold a limited amount of data (Ingredients, Formulas, etc) at one time. WebCentral stores data in a Microsoft SQL Server (or SQL Express) database. A virtually unlimited amount of data can be stored. WebCentral monitors key processes and batching data and alarm conditions in the automation system. It provides logging and historical analysis of this data. PLC’s and Control Systems are good at controlling equipment. Computers and Databases are good at managing data. WebCentral provides the means to bridge these two worlds. This provides a seamlessly integrated automation solution.

Plantwide Systems – Automation – Food, Feed, Other Industrial:

Plantwide Systems – Key Features:

  • Plantwide automation systems integrate into business systems with either proprietary or non-proprietary software
  • Incorporates standard or custom features required by each process control application
  • Accommodates Wonderware, Intellution and other industrial software packages
  • Scheduling
  • Formulation Management (ingredient batching applications)
  • Raw Material Management, Inventory and Usage
  • Material Parameters (Tolerance, Feeder Speed, Jog, and Pre-act/Cutoff…)
  • Product Safety – Raw Material Lot Tracking (Bar Code, RFID)
  • Process Validation (Bar Code, RFID…)
  • Equipment Parameters (Scales, Mixer, Dry Ingredient Feeders, Liquid Meters…)
  • Finished Batch Tracking
  • Abnormal Condition Alarms and Tracking
  • Remote Batching & Data Access Software (WebCentral)
  • Troubleshooting & Diagnostics Features (Local & Remote)
  • Least Cost Formulation Software Interfaces

Plantwide Systems – Feed Mill:



Grinding System:
  • Grinding System Automation Screen (Feed Mill example)
  • Pre-Ground Product Storage Routing To Grinding BinsBLENDING MIXING
  • Grinding Bins Level Control
  • Feeder Speed Varied Automatically based upon Mill Load
  • Grinding Equipment Monitoring for Maximum Throughput
  • Equipment Monitoring for Abnormal Conditions & Run times
  • Auto Routing of Ground Product
Batching System:
Pelleting System (Feed Mill application):
  • Pellet Mill Automation Screen
  • Amps
  • No Roll Slip
  • Pellet Mill Inlet Mash Temperature
  • Steam Modulating Valve
  • Lineator Roll Gap Software and I/O
  • Equipment Monitoring for Abnormal Conditions & Run times

    Pellet Mill Monitoring
  • Pellet Mill Setup Screens (password protected)
  • Parameter Storage for Operating Formula and Pellet Mill:
    • Operating instructions
    • Run setpoints
    • Amps
    • Temperatures
    • Speeds for the pellet mill
  • Unique parameters Stored for Multiple Formulas
  • Liquids can be controlled by the PELLET MILL workstation.
  • Liquids Added either at the Conditioner or Die
  • Auto/Man – Operate Manually and Switch to Auto “on the fly”
Loadout Systems:
  • Railcar/Truck Loadout Automation Screen (truck loadout shown here)LOADOUT
  • Scale Integration
  • Shuttle Conveyors or Trolley Systems
  • Multiple Compartment Filling
  • Truck Tracking
  • Customer Tracking
  • Finished Product Tracking



Working With Us

Give us a call today to talk about your business and process objectives and see how Sterling Systems & Controls can provide a custom engineered solution.  You can reach us by phone at 1-815-625-0852, toll-free in the USA 1-800-257-7214, or by email at