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Ridley Block

Flemminsburg, KY

Expanding an existing facility to better serve livestock producers.

Project Details

Industry

Feed Mill

Construction Type

New Construction Design-Build

Services Performed

Electrical Design, Installation and Automation

Labor

100% Self-Performed by Knobelsdorff

Project Duration

March 2021 - April 2022

Technology

Rockwell Automation, Inductive Automation Ignition and CMC

Panels

PLC, HMI, Screwfeeder VFD, Scale Control Panel for Hand-Adds

Summary of Work Performed

The Situation

Ridley Block Operations (RBO), an Alltech company, manufactures and markets block supplements, loose minerals and dried molasses for a variety of livestock. RBO is the largest manufacturer of block forms, and it is recognized as the industry leader in block supplements. It turned to Knobelsdorff when it expanded its livestock feed supplement low-moisture block manufacturing at its Flemingsburg, Kentucky, plant.

The Solution

Knobelsdorff provided electrical design and installation for a complete electrical system on the project, including the installation and termination of:

  • New MCC's to accommodate new equipment
  • All motors, including conduit/wire, local motor disconnects, and startup and commissioning
  • Complete grounding system for new infrastructure and equipment
  • New 480v to 120/208v dry-type transformer
  • Two 120/208v 225-amp panelboards to accommodate new lighting, controls and convenience receptacles

KE also provided design and engineering for the controls and automation system, as well as programmed the PLC and SCADA to support the new system. Additional components of the job included:

  • Installation of a CMC Hazard Monitoring System
  • Network diagram, control panel layouts and schematics
  • Full control system package with CompactLogix PLC control panel with Stratix managed Ethernet switch
  • SCADA operator stations with automation ignition technology with future integration into Dynamics ERP
  • Local batching recipes and records for batching processes
  • Complete startup, commissioning and customer training of the control system
  • Design and engineer Hand Add system and update existing stations to include tighter integration with the control system
  • Field instrumentation for plug switch, speed switch, CMC Hazmon leg kit, high- and low-level sensors, weight indicators, and current transmitter for monitoring motor amps
The Result

The new facility will help reduce freight costs for RBO customers and improve RBO's ability to respond more quickly to customer demands for low-moisture blocks in the eastern U.S. and Canada. RBO now utilizes a KE Fully Automated Customized Grain System, which includes:

  • Equipment control
  • Automatic routing
  • Bin inventory
  • Hazmon integration
  • Configuration and ease-of-use
  • Security

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