Feed Mill Automation

Turn Over-the-Hopper into Turnkey Production

Feed mill automation can simplify operations, reduce cost and increase throughput for almost any feed-processing facility. Sterling Systems & Controls custom-engineers full feed-mill solutions (or subsystem upgrades) for cattle, poultry, swine, equine and specialty feed operations.

Why Automation Makes a Difference

• Manual or semi-manual mills face labor, error, and traceability risks.
• Automation links receiving, grinding, batching, pelleting, load-out and truck-scale systems under one control, improving safety, consistency and efficiency.
• Data capture: ingredient & vendor tracking, recipe/lot traceability, inventory management and remote access.

What Sterling Delivers

• Custom automation hardware & software built on Allen-Bradley PLCs, Windows-based PCs, and Sterling’s library.
• Modular process coverage: receiving/transfer, grinding, batching (micro/minor/major), pelleting, load-out/truck scale.
• SQL-based database and remote-supervisory WebCentral for real-time data and historic analysis.

Typical Automation Modules

• Receiving & Transfer: truck/rail scale, routing, inventory logging.
• Grinding Control: hammer/roller mills, schedule-driven, throughput monitoring.
• Batching & Mixing: recipe control, simultaneous scale use, database history.
• Load-out & Shipping: correct product/truck routing, sensor verification, automatic reporting.

Frequently Asked Questions

What is feed mill automation?
Feed mill automation is engineering and system integration that controls batching, material handling, weighing, and process sequencing throughout the feed production flow using PLC/HMI or HMI/SCADA platforms and custom control panels.

What parts of a feed mill can Sterling automate?
Sterling automates ingredient receiving and transfer, weighing and batching, mixers, conveyors, elevators, loadout systems, and upstream/downstream equipment. The goal is tighter control over formulations, throughput, and consistency.

Does Sterling integrate data tracking into feed mill systems?
Yes. Sterling’s systems can capture production data, recipes, batch history, alarms, and events into SQL databases, historians, or data services for reporting, traceability, and analytics.

Can Sterling work with existing equipment in a feed mill?
Yes. Sterling evaluates current mechanical and control systems to determine where software upgrades, PLC/HMI changes, and panel redesigns can optimize performance without unnecessary replacements.

How does feed mill automation improve consistency and efficiency?
By coordinating weighing, batching, material handling, and control logic, automation reduces manual steps, improves tolerance control, increases throughput, and provides operator visibility with centralized control interfaces and reporting.

Why Choose Sterling

• Over 50 years of automation experience in feed & related industries.
• Single-source integration of hardware, software, panels and system logic.
• Global support and long-term service commitment.

Ready to automate your entire feed-mill line or upgrade key subsystems? Contact us for an application review and we’ll map the automation architecture to optimize throughput, traceability and value.