Plantwide Systems


Sterling Systems & Controls, Inc. offers complete customized plantwide process control and automation systems solutions for a wide range of industires.  Example: Feed is produced for nearly every domesticated animal, including petfood 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 automation systems for the feed mill industry/facility. Also, it offers automation and control for individual aspects of the manufacturing process. In addition, Sterling Systems can provide fully integrated plantwide systems as turn key.

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 just 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. Nearly unlimited amount of data can be stored. WebCentral monitors key process and batching data and alarm conditions in the feed mill 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 turn key feed mill automation solution.

Plantwide Automation:

Key Features:

  • Plantwide automation systems integrate into business systems with either proprietary or non-proprietary software
  • Incorporates standard or custom features required by each feedmill process control application
  • Accommodates WonderWare, Intellution and other industrial software packages
  • Scheduling
  • Formulation Management & Storage
  • Raw Material Management, Inventory and Usage
  • Material Parameters (Tolerance, Feeder Speed, Jog, and Pre-act/Cutoff…)
  • 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


Grinding System

  • Grinding System Automation Screen
  • 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 Condition & Run times
  • Auto Routing of Ground Product

Batching System

Pelleting System (feedmill systems)

  • 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 Setup Screens (password protected)
  • Parameter Storage for Operating Formula and Pellet Mill:
    • Operating instructions
    • Run set-points
    • 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 in 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