We’re proud to announce the successful completion of the Scenic City project—an industrial automation initiative that modernized drying operations at a major agricultural processing facility in Iowa Falls.
Upgrading Legacy Systems
The project centered on replacing an outdated bean dryer with a new unit supplied by a specialized vendor. To support this upgrade, our team developed a custom PLC program and HMI interface tailored to the new equipment. This ensured seamless integration with existing plant operations and met both vendor and client standards for performance and quality.
Seamless System Integration
New components—including bucket elevators and conveyors—were incorporated into the facility’s existing control system. This integration was designed for ease of use and operational reliability, minimizing disruption while maximizing efficiency.
First-of-Its-Kind Control System
This project marked the first time our team implemented a ControlLogix-based control system for this specific dryer model. The successful deployment sets a strong precedent for future installations and programming efforts involving similar equipment.
Safety, Documentation, and Reliability
We worked closely with plant stakeholders to coordinate interlocks and develop comprehensive documentation, ensuring safe and reliable control of the dryer and elevator systems. Custom-built control panels were also deployed to support instrumentation and system control.
Fast-Track Commissioning
Thanks to strategic planning and cross-functional collaboration, the commissioning phase was completed in record time—one of the fastest ever achieved for a project of this scale. Post-commissioning, our automation team ensured smooth operation and consistent performance of the new system.
This project stands as a testament to the power of teamwork, technical expertise, and innovation in delivering high-impact solutions on an accelerated timeline.
Written by: Matt Jones, Account Manager, ESCO Automation