How Engineered Solutions Streamline Industrial Automation

Introduction

In the world of industrial automation, staying ahead means constantly refining processes to boost efficiency and minimize errors. Traditional methods of integrating new components into existing systems have their place, but they often fall short of addressing the unique challenges each operation faces. Enter engineered solutions—tailored systems that go beyond integration, offering comprehensive automation for maximum performance. At Brechbuhler Scales, our Engineered Solutions provide a pathway for industries to streamline their operations, reduce human error, and adapt to ever-changing demands.

In this blog, we will explore how engineered solutions differ from traditional systems integration and examine a real-world example of how Brechbuhler’s approach to automation significantly improved a bulk cement loadout system.

Automation vs. Systems-Based Approach

When companies think of automation, they often start by considering how to integrate individual components—like scales or sensors—into their existing systems. This is the foundation of what’s known as a systems-based approach. While it focuses on connecting these elements, its scope is often limited to enhancing specific parts of the process without addressing the broader operational inefficiencies.

Engineered solutions, on the other hand, take a holistic view. Instead of simply adding components to a pre-established framework, Brechbuhler Scales works to redesign and automate entire processes. We assess how every element—from hardware to software—can be optimized. This means that instead of making the process fit around the equipment, we create a solution that addresses the entire workflow, resulting in a system that is more efficient, flexible, and tailored to the client’s needs.

The Benefits of Fully Automated Systems

One of the most significant advantages of fully automated systems is the improvement in operational efficiency. When a process is automated from end to end, the system can work seamlessly without the need for manual intervention, reducing the risk of human error. Automation also ensures that every aspect of the process runs smoothly and consistently, leading to fewer bottlenecks and higher overall productivity.

For example, Brechbuhler’s solutions extend beyond simple data collection from truck scales or in-motion checkweighers. We design systems that streamline operations like truck loading, batch control, and conveyor checkweighing. These automated systems eliminate many of the variables that lead to inefficiencies, allowing clients to focus on what they do best—running their business.

By utilizing Brechbuhler’s engineered solutions, companies can optimize their processes, reduce downtime, and ultimately lower operational costs. Fully automated systems reduce the need for constant human oversight, and errors that are often associated with manual data entry or operation can be minimized.

Case Study: Cement Loadout System

One of the best examples of how Brechbuhler’s engineered solutions have transformed operations can be seen in a recent project for a bulk cement company.

Challenge: The client needed to streamline their bulk cement loadout process. They were facing inefficiencies with manual processes and outdated equipment, which led to frequent errors, slower loadout times, and unnecessary downtime.

Solution: Brechbuhler proposed a custom-engineered solution that fully automated the loadout process. The system was designed to control two cement silos and a truck scale using EtherNet/IP mapping. The integration was seamless, with a Brechbuhler-engineered PAC handling all the logic for the filling process. This system allowed for real-time communication between the silos, truck scale, and operators, drastically reducing manual input.

Outcome: The new system resulted in faster loadout times, more accurate measurements, and a significant reduction in operational errors. By automating the entire process, the cement company was able to improve throughput, reduce downtime, and cut costs associated with manual operations.

Flexibility and Customization in Engineered Solutions

Brechbuhler’s engineered solutions are built to be flexible and highly customizable. Whether you’re running a packaging line, a truck scale system, or a bulk material handling process, Brechbuhler can design a solution tailored to your specific needs. Our engineered solutions are not just about integrating scales; they are about creating an entire system that works in harmony to improve your overall efficiency.

From RFID integration to PLC-controlled batching, Brechbuhler offers solutions that fit a variety of industries, including manufacturing, logistics, and food and beverage. Each project is designed with flexibility in mind, allowing our systems to adapt to future growth and operational changes.

The Process of Developing Engineered Solutions

At Brechbuhler Scales, we follow a comprehensive, full-service approach to engineered solutions. Here’s how it works:

• Project Discovery and Site Visits: Our team works closely with clients to understand their needs. This often includes a site visit where we can assess the current systems, discuss pain points, and gather all the necessary information.
• Engineering and Design: Once we understand the client’s needs, our engineering team gets to work designing a solution. This includes selecting hardware, designing the control systems, and mapping out how the entire process will be automated.
• Solution Presentation: We present our proposed solution to the client, making any adjustments based on their feedback. Once the concept is approved, we move into the detailed design phase.
• Installation and Training: After the system is designed, we handle the installation and provide on-site training to ensure that the client’s team understands how to operate and maintain the system.
• Ongoing Maintenance and Support: After installation, we continue to provide support, ensuring that the system runs smoothly. Any necessary tweaks or updates are handled quickly, allowing the system to maintain peak efficiency.

This hands-on approach ensures that every engineered solution is tailored to the client’s needs and can adapt to future challenges.

Conclusion

Brechbuhler’s engineered solutions are more than just systems integrations—they are fully customized, turnkey solutions designed to improve efficiency, reduce operational errors, and provide long-lasting benefits to our clients. Whether you need a simple scale system or a fully automated loadout process, Brechbuhler Scales is committed to delivering innovative solutions that meet the specific needs of your industry.

Ready to transform your operations? Contact Brechbuhler Scales today to learn more about how our engineered solutions can streamline your processes and set you on a path to greater efficiency.