Animal Feed Process Control System

Simple and Intuitive

Imperium4Feed offers an intuitive graphical web interface, accessible from any device with a browser, making it ideal for managing feed mills and animal feed production. The web pages are hosted on a local server, safeguarded by the client’s firewall and network security, ensuring robust data protection.

Unlike cloud-based solutions, it operates independently of an internet connection, providing uninterrupted control over critical feed production processes. Reliability, alongside usability and optimization, is at the heart of Imperium4Feed's architecture and design, delivering a seamless, efficient solution for feed mills.

Screenshot of a feed management software interface displaying a system diagram labeled 'Receiving 2.' The interface includes controls for starting intake, selecting material code, destination bin, and ingredient bin. Various bins and pipes are illustrated, with operational status indicators and a confirm diverter option. The logo 'Imperium4Feed' is visible at the top right.

Imperium4Feed Overview

  • Overview

    Imperium4Feed is a process control, planning and information system that is designed specifically for feed and grain plants, including animal feed mills, pet food plants, pre-mix plants and grain silo storage. Imperium4Feed is simple and intuitive to operate. It provides highly sophisticated techniques to optimise production and allow unmanned operation where possible. Imperium4Feed is fully user-configurable and built from a number of modular blocks to control your plant. This includes the intake of raw materials, blending, grinding and mixing of batches, pellet press /extruder control and bulk outloading / packing.

    The system is fully scalable and can be configured for all mills, from a simple blend shed through supervisory guidance of operators of highly complex super mills. It may be used to control one area of a plant initially and then be extended as circumstances permit. Many modifications can be made to the system even while production is running

  • Front to Back Control

    Imperium4Feed may be used to control:

    Weighbridge in, intake/receiving, silo transfer, weighing and batching, hand weighing, grinding, mixing with liquids control, pellet press control, routing to finished product bins, fats coating/PPLA, bulk outloading, packing, warehouse and weighbridge out.

    Imperium4Feed has a built-in simulation system allowing you to test and facilitate operator training via a digital twin of your process. When the system is configured with real-time Digital Twin parameters, it can be used to help engineers redesign a plant and diagnose potential bottlenecks.

  • Standard Hardware & Mobile Control

    Imperium4Feed operates on standard Microsoft Windows PCs and easily connects to various PLC and Input/Output systems, including Allen Bradley, Mitsubishi, and Siemens. This capability enables economical upgrades of competing or legacy process control systems with minimal disruption and wiring modifications by utilizing existing PLCs.

    For larger systems, a Windows server can be employed, with Thin Client PCs designated for operator workstations. Thin Client computers are ideal for industrial settings as they lack a hard disk, making them simpler to set up and more robust and reliable.

  • Logging & Reporting

    Comprehensive management information is recorded by Imperium4Feed and can be accessed using online viewing programs or printable reports which may be customised using the Crystal Reports package. All data is stored in an open SQL server database.

    Imperium4Feed will log all intake transactions, batch records, stocks audits/alarms, usages, production, pellet press/extruder runs and out loading transactions. This data is stored online for up to seven years and can be viewed with Imperium4Feed’s simple-to-use facilities. This satisfies most site requirements and helps mills to achieve the required quality standards and approvals. Data may be printed and can be exported to a spreadsheet of another computer system.

  • Intergration

    Imperium4Feed has facilities to integrate with a wide variety of IT, ERP and formulation systems in the following areas:

    Intake/Receiving

    Order and production

    Batch production details

    Outloading truck operations

    Bin/Silo contents

    Formulation, declaration and product information

    Imperium4Feed has been successfully integrated with Format International, Microsoft Dynamics, Adifo/Bestmix, CORE Software, Culture, SAP, Pegasi, ICS Perito, Feed Management Systems (FMS), Brill, Agris, M-Tech, Pegasus Opera in addition to many bespoke and local systems.

See Imperium4Feed Brochure
  • Stylized clock with orange concentric circles

    24/7 Support and Built-in Redundancy to Minimise Downtime

  • Illustration of a hand icon pressing a red target button

    Browser Based User Interface

  • Two interlocking orange gears inside a white outlined circle on a black background.

    User Configurable

  • Infinity symbol with concentric circles

    Software For Life

  • Stack of books icon in orange outline within a circular frame on a white background.

    Reduces Operator Workload

  • Expandable For Any Future Plans

Integrated Modules

OEE4Imperium Logo | Process Control System
Dashboard showing plant summary and performance metrics including availability, performance, quality, and Overall Equipment Effectiveness (OEE). Includes production statistics and graphs for various press lines with details on total production, efficiency, and more, on a blue background.

OEE4Imperium is a web based performance monitoring system designed specifically for feed and grain plants. The system collects data from the Imperium4Feed local control system and displays OEE (Overall Equipment Effectiveness) and KPIs (Key Performance Indicators) on a web page. The data can be drilled down to reveal more detailed data. The web page can be accessed on a local intranet or exposed to the internet for global access. The system can be set-up with user security to prevent unauthroised access.

CMMS4Imperium Logo | Process Control System
A screenshot of a work order management dashboard from a software called CMMS4Imperium. It displays a work order summary with categories such as Unassigned, Completed, Not Started, and In Progress, along with their counts. Below, there is a table listing work orders with details like Job, Parent, Ident, Ident Description, Area, Title, Priority, Status, Due Date, Updated Date, and Attachments/Forms. The sidebar includes navigation options such as Dashboard, Work Orders, Faults, Planned Maintenance, and more.

CMMS4Imperium provides a method of recording information on all site equipment which may be used as an aid to planned and unplanned maintenance. It also provides a means of storing supplier information and sub-assemblies in stores. If linked to an Imperium4Feed control system, equipment run times and other totals such as the number of times a certain item has been started are updated automatically; therefore maintenance schedules are automatically updated too. Equipment faults can be reported by the operator by clicking on the item which in turn automatically creates a maintenance task.

Plan4Imperium Logo | Process Control System
Screenshot of a software interface featuring order scheduling for agricultural feed production. The top section displays an order list with columns such as product code, amount, and required dates. A tooltip provides details about a specific product blend. The bottom section shows a production program timeline with color-coded plans for different production lines.

Plan4Imperium is designed to simplify the process of scheduling orders for production by visually displaying the production programme on a timeline and highlighting any potential problems. Plan4Imperium makes scheduling and planning simple and quick, prevents scheduling mistakes, warns of orders which are going to be late and minimises flush batches and die changes.

WMS4Imperium Logo | Process Control System
Warehouse stock tracking software screen displaying shipment details, including FLT number, load note, delivery note, customer information, product weights, codes, and locations. Features options to remove broken bags or move location. Date and time displayed at the top.

The Warehouse Stock Tracking option is simple to operate and yet provides substantial benefits. Every time a pallet is produced, a barcoded ticket is printed and stuck onto the pallet. When a truck arrives to collect a delivery, a wireless tablet PC is used by the forklift truck (FLT) driver. After entering the order number, the FLT driver wands the barcode of the pallets or part pallets collected. Codes and stock levels are instantly checked, preventing incorrect operations such as shipping the wrong pallet or missing items. A complete and accurate stock record is always maintained, and details of all deliveries are logged. A variety of reports and printouts are available as standard. The system works with pallets of small bags, big bags, raw materials, finished products, packing materials and consumables - whatever you have in your warehouse.

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