René SMULDERS , KSE Process Technology :Our process control system Promas ST grows along with a factory. Due to its flexibility, this automation solution is particularly future-proof. If a factory must be renewed or updated, it is possible to implement adjustments wit Promas ST in small, profitable steps. Expensive investments in new automation systems are therefore a thing of the past.”
KSE which was founded in 1973 by the Smulders family has Alfra dosing and weighing solutions, covering everything from micro up to macro components, with dosing ranges from 20 gram to above 6,000 kg in their portfolio. The company which has launched Promas automation software to fully control the production process in 1988 provides full automation solutions for customers in animal feed and food industry factories.
KSE supplies machines, automation systems and services for every phase, from intake to outload, helping feed producers to meet the demand of livestock farms in a cost-effective way.
Commercial Director of KSE Process Technology, René Smulders who states KSE’s main innovation in the past years has been contamination free transport by using a containerized system, explained the latest innovation they are working on is aimed at replacing the large quantity of manual hand tips. René Smulders shared services of KSE for feed industry, products in their portfolio and the latest innovations with us.
KSE Process Technology is the supplier of dosing and weighing systems, automation solutions and services for producers of powders, granulates and liquids in the animal feed industry and related industries. If you don’t mind, could you please tell us about the story of KSE Process Technology and how it achieved today’s success?
KSE was founded in 1973 by the Smulders family. Soon after, we have welcomed several major customers from the animal feed sector. In 1988, we have launched our Promas automation software to fully control the production process for the customers and later became market leader in the Netherlands and Belgium in the field of industrial automation in the animal feed industry, resulting in the acquisition of Alfra Doseer- en Weegsystemen B.V. in 1997.
Despite our worldwide activities, KSE remains a family business to the core. Personal contact, excellent service and passion for the feed processing industry are still key. Our top priority is good collaboration, with our customers but also with our partners worldwide. Because only through close partnership with all stakeholders, we can truly optimize production at the customers.
Could you give information about your product groups and solutions in terms of dosing and weighing systems and automation software?
Our portfolio contains Alfra dosing and weighing solutions, covering everything from micro up to macro components, with dosing ranges from 20 gram to above 6,000 kg. Our future-proof Promas ST Process control system completely automates animal feed and food industry factories.
Could you tell us the phases that dosing and weighing systems used in feed mill? What is the importance of dosing and weighing systems in feed mill? Could you give us the information about purposes of dosing and weighing systems in every phase?
The scale of livestock farms continues to increase. As a result, the need for efficient and flexible solutions in the feed industry is growing. KSE supplies machines, automation systems and services for every phase, from intake to outload, allowing feed producers to meet the demand of livestock farms in a cost-effective way:
Phase 1 – Intake of raw materials: The intake of raw materials can be done in various ways. Think about ship intake, pneumatic intake or for instance via bags. With our ALFRA intake systems, you can easily take in several raw materials from a truck and make several weighing at the same time.
Phase 2 – Dosing & weighing: The operational demands on a dosing and weighing system will only get tougher in the coming years. Producers are looking for more speed, higher accuracy and a larger number of ingredients per product. At the same time, they are under constant pressure to produce more at a lower cost without compromising quality. Exactly for this problem KSE has developed a wide range of Alfra dosing and weighing systems.
Phase 3 – Internal transport: With internal transport, feed producers must be able to do both horizontal and vertical transport. The requirements in product safety, energy consumption and contamination are becoming stricter. Contamination is a major disadvantage of conventional transport such as elevators or chains. Due to increasingly stringent requirements, the contamination must be reduced. With the internal transports of Alfra, contamination can be reduced to zero.
Phase 4 – Pelleting / finished product handling / Bulk outloading: The process of bulk outloading has a wide diversity of executions. Automating this process step requires a great deal of know-how. Alfra has bundled this know-how in systems that will enable you to automate your bulk loading.
Could you tell us about the benefits of implementing an automation technology in a feed mill? According to you, what processes are more suited for automation?
The animal feed industry has globalized and consolidated, meaning competition has become fiercer. And like all industries, there is constant pressure to reduce costs without compromising quality. KSE meets these challenges with custom-made systems and solutions that can be cost-effectively upgraded as the client’s business grows.
Our process control system Promas ST grows along with a factory. Due to its flexibility, this automation solution is particularly future-proof. If a factory must be renewed or updated, it is possible to implement adjustments wit Promas ST in small, profitable steps. Expensive investments in new automation systems are therefore a thing of the past.
Automation gives the ability to trace the product throughout the process so that any operator error can be observed. Or once a system is fully commissioned, an automation system consistently performs a repetitious task at high accuracy levels, while never getting distracted. Regarding the benefits of automation system in a feed mill, what do you think about the automation’s help in promoting feed safety?
By logging all relevant information, the automation system can create reports regarding material movement, alarms and manual actions for every product. In case of a problem the customer can pinpoint the problem and act. Safety around manual actions and displaying warnings and errors is part of the automation. All with main goal of feed safety in mind.
Could you tell us about the support you provide after installation? Is there a remote support system to provide help to the customer when needed?
KSE provides 24/7 customer support. The services range from telephone help lines and on-line support to maintenance contracts with pre-agreed response times and guaranteed availability of spare parts. Training programs and documentation are also offered. If necessary, KSE technicians will remotely log onto customer systems to solve problems directly or preventively. KSE has many international customers and each of them works with Promas ST in their own language. Our service employees who login remotely also see the control panel in their own language, regardless of the language of the automation system of the customer. This multi-language feature ensures that our service employees can remedy any unexpected failure or stagnation faster. Statistics prove that 95 % of the errors are solved remotely.
Can you now talk about your latest innovations and the benefits these innovations will bring to the industry? What are the new technologies that you wish to introduce to the feed producers in the future?
KSE’s main innovation in the past years has been contamination free transport by using a containerized system. The latest innovation we are working on is aimed at replacing the large quantity of manual hand tips, this innovation will be an addition to our silo based weighing solutions.
What about the energy efficiency? Could you give us some information about energy-efficiency of your solution?
KSE uses gravity to dose raw materials; therefor the energy consumption is minimal compared to mechanically driven dosing systems.
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