Gray partnered with Scoular—a 127-year-old company with a focus on global distribution of grain, feed ingredients, and food ingredients—on the company’s first manufacturing venture into pet food. The customer announced its investment in Petsource—an indirect, wholly-owned subsidiary—in March 2019 and selected Gray to provide fully integrated services for a greenfield facility in Seward, Nebraska.
The manufacturing plant produces high quality freeze-dried pet food ingredients and includes a warehouse, cold processing rooms for raw meat, freeze dryers, and packaging rooms.
Gray Solutions worked in conjunction with Gray to drive the successful completion of this project by providing process expertise through the use of technical consulting. By executing processing engineering and process controls/automation services throughout the project, Gray Solutions supported Petsource from equipment procurement and construction execution through commissioning and startup.
Project services included development of an Ignition application to monitor and display room temperature from the building refrigeration system. This application allows the room temperature information to be stored and correlated to the running batch using date and time. With this tool, Petsource has the ability to monitor process-critical room temperatures from remote locations and allow personnel to be notified of upset conditions in time to prevent a significant temperature upset.
Gray Solutions also developed an Ignition application to monitor and display information from the wastewater treatment system. This application allows the system to be monitored from the main plant. The wastewater treatment system continues to control the process locally, but Petsource personnel now have greater visibility into the process from remote locations.
All alarms are set to allow for them to be emailed or sent over SMS messaging to a configurable list of recipients. Historical data is stored in a SQL database, and Gray Solutions will continue to work with Petsource IT to incorporate this data into the plant-wide historization.