Nutrien Clyde-GFS-Fertilizer Blending Plant

The Project

GFS Projects contacted us about a new Fertilizer and Blending facility they were building for Nutrien Ag Solutions in Clyde, Alberta. They were looking for an electrical contractor who specializes in electrical automation solutions and contacted Current Group because of our experience with other similar fertilizer and grain handling facilities. AGI Fertilizer Systems designed the facility utilizing AGI’s Declining Weight Blend System with an LV Controls Fertilizer Blending Control Panel.

How does a fertilizer blending plant work?

A fertilizer blending plant is a facility where different fertilizer materials are mixed together in specific proportions to create customized blends tailored to the nutrient requirements for particular crops or soil conditions. Here’s how it generally works:

Receiving and Storage: Various raw materials such as nitrogen (N), phosphorus (P), potassium (K), sulfur (S), micronutrients, and other additives are received at the blending plant. These materials often come in the form of granules, powders, and are stored in large bins. The Clyde facility uses 14 large bins to store the raw materials.

Material Handling and Preparation: Before blending, the raw materials are received and stored in individual component bins.

Formulation: Based on the specific nutrient requirements of the target crops or soil conditions, a formulation is created specifying the proportions of each raw material needed in the blend. This formulation considers factors such as soil test results, crop type, growth stage, and desired nutrient ratios. A Crop Agronomist or Crop Advisor works with the farmer, testing their land to determine what nutrients are lacking in the soil. They then determine a fertilizer blend of NPK and a fertilizer rate to apply on each field to minimize their crop input cos

Blending: The raw materials are then accurately measured and mixed together using the AGI Declining Weight Blending System. This system uses precision metering devices and an optimized control system for the required Nutrient fertilizer products (NPK). The custom blend formulation is specified by the Customer’s Agronomist and entered into the blend system PLC control panel through an electronic keypad.

The automation control system sends the rate information to the equipment controls, then continuously monitors the process to ensure a precise and accurate blend of fertilizer.

Quality Control: Throughout the blending process, quality control measures are implemented to ensure that the final product meets the desired specifications. This may involve sampling and testing the blended fertilizer for nutrient content, particle size distribution, moisture content, and other quality parameters.
Packaging and Distribution: Once the fertilizer blend has been thoroughly mixed and quality tested, it is sent to a loading bin where it is loaded onto a truck to be shipped to the farmer.

A Nutrient fertilizer blending plant can produce custom fertilizer blends tailored to the specific needs of farmers, thereby optimizing crop yields and promoting sustainable agriculture practices.

Services Provided

The project was a partial design build or “design assist” because Nutrien and GFS Projects have a standard design they follow at all their fertilizer blending facilities. Our design scope of work was to work with all suppliers to create a concise electrical power and control installation. Through a consultative approach through the design phase, we managed to find opportunities to save costs on the electrical installation.

The job started with the electrical rough-in where a cable tray and LED lighting were installed while the fertilizer equipment was set in place. While the general contractor was installing the equipment, the main distribution panels, MCC panel, and PLC control panels were installed. Next electrical power cables were run to all equipment motors. The next step is to run the control wires from the electrical control panel to each end device. The Declining Weight Blending System uses many sensitive hopper load cells and combines this with conveyor speed sensors to measure the amount of each fertilizer component in the blend. Continuous monitoring of the conveyor RPM ensures accurate blends. Finally, after the main power service is connected, each end device is tested to ensure the PLC program functions as designed.

As winter approaches, cattle ranchers face the critical challenge of ensuring their herds maintain optimal health and growth despite the harsh conditions. One often overlooked factor is the temperature of drinking water, which plays a significant role in the overall well-being and productivity of range cattle during cold months. In this article, we will explore how water temperature impacts water consumption and growth performance and how Current Group’s Open2O cattle trough heater can make a difference by preventing freezing and ensuring water availability.

The Impact of Access to Water on Cattle Health

Research consistently shows that water availability is critical to cattle’s water intake, especially during winter. Frozen water can drastically reduce consumption, as cattle cannot access the necessary water. This leads to dehydration and increased energy expenditure, as cattle use more energy to maintain their body temperature in the cold.

This increase in water intake is crucial because it correlates with higher dry matter intake (DMI), which is essential for maintaining body weight and overall health during the cold season.

According to Jon DeClerck, Ph.D., cattle nutritionist with Purina Animal Nutrition, “Water is the most essential nutrient for cattle production,” says “It’s used for regulating body temperature, growth, reproduction, lactation, digestion and many other bodily functions. Water also drives intake for mineral, forage and supplements. And while we typically worry more about water intake in summer, it’s equally as important in cold weather.”

“For fall calving herds, water requirements go up drastically during lactation. Cows hit peak lactation right when water is at risk of freezing up. With spring calving herds, water access is key to avoid stress and long-term performance impacts to both the cow and unborn calf.”

Consequences of Inadequate Water Intake in Winter

When cattle do not have consistent access to water due to freezing conditions, the consequences can be severe. Insufficient water intake leads to dehydration, reduced feed intake (which affects nutrition), and poor growth performance. Instead, energy that should be used for growth is used to maintain body temperature, leading to weight loss and a decline in body condition. Additionally, water shortages can disrupt rumen fermentation, nutrient absorption, and overall cattle health, further compromising productivity.

Ideal Water Temperature and its Effect on Your Herd

Ensuring that water is available to cattle throughout winter is crucial to their hydration and growth. However, a balance needs to be met in terms of your water temperature.

Kate Hornyak, OSU Extension Program Coordinator, Delaware County, says, Keeping the ideal temperature of drinking water for cattle is a balance – it should neither be hot nor frozen.” – “It’s interesting to note that steers with access to cool drinking water have shown to gain an additional 0.3 to 0.4 pounds per day compared to those consuming warmer water. This underscores the importance of regularly checking the temperature of water, especially in waterers equipped with heaters, to avoid what’s known as a “runaway” – a situation where the water gets too warm.”

Cattle Trough Heater Open2O: Preventing Frozen Water

To address the challenges of water freezing during the cold season, Current Group offers the Open2O advanced electric device, an innovative solution designed to monitor water temperature and regulate the power to the heating element. Unlike traditional heating systems that continuously warm water, Open2O ensures that water remains just above freezing, reducing energy consumption and ensuring that cattle always have access to water.

Features of Open2O Water Controller

Power Savings: The Cattle Trough Heater Open2O has multiple temperature inputs, which allows it to monitor water temperature every 30 seconds and turn on the heating elements only as needed. This optimized control has been proven to cut substantial power usage, with an estimated minimum of 53% power savings.
Real-Time Water Consumption Report: The Cattle Trough Heater Open2O system provides real-time reports on water consumption, which allows cattle operators to monitor water intake per animal. This data helps identify potential issues early on, as it compares water usage across different troughs, signalling if a problem arises with any specific bowl. Accurate water consumption data supports better animal health analysis, ensuring every animal is adequately hydrated.
Alarm Options for Consumption and Temperature: The Cattle Trough Heater Open2O has alarm options that alert operators to unusual consumption patterns—whether too high or too low—indicating potential issues like a broken water line. The system also notifies operators if the water temperature drops too close to freezing.
Labour and Stress Reduction: With Open2O’s remote monitoring capabilities, feedlot operators no longer need to send staff out in cold temperatures to check water bowls. Instead, they can view the software and confirm that all water sources remain open, reducing labour costs and management stress year-round.

With these features, Open2O provides a comprehensive solution to prevent water bowls from freezing, monitor water consumption, and support cattle health through the cold months.

Critical Benefits of Cattle Trough Heater Open2O

Prevents Water from Freezing: Open2O ensures that water remains accessible, avoiding water freezing in bowls.
Energy Efficiency: By regulating the power to the heating element, Open2O conserves energy, reducing costs while maintaining water availability.
Durability and Reliability: Built to withstand harsh winter conditions, Open2O ensures uninterrupted access to water throughout the cold months.
Improved Growth Performance: By preventing frozen water, Open2O supports cattle hydration, feed utilization, and overall growth performance.

Providing unfrozen drinking water during winter is more than just a comfort for cattle—it’s essential to maintaining their health and growth. With the Open2O device from Current Group, ranchers can ensure that their cattle have continuous access to water, even in the coldest months. Invest in cattle trough heater Open2O today to secure your herd’s health and boost your bottom line this winter.

Agricultural Automation, Agricultural Industry, Case Study

Nutrien Clyde-GFS-Fertilizer Blending Plant

The Project

How does a fertilizer blending plant work?

Services Provided

The Impact of Access to Water on Cattle Health

Consequences of Inadequate Water Intake in Winter

Ideal Water Temperature and its Effect on Your Herd

Cattle Trough Heater Open2O: Preventing Frozen Water

Features of Open2O Water Controller

Critical Benefits of Cattle Trough Heater Open2O

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