Transforming Storage Solutions: A Case Study from Summer of 2022
In the summer of 2022, Top Bead undertook an ambitious project at a local Feed Mill in Virginia. We successfully completed the installation of a 1,000-ton ingredient storage bin. This project was a key component of a larger expansion effort at the feed mill aimed at optimizing its storage capabilities and streamlining its operations.
Extensive planning was essential before we could assemble the structure and storage bins. The initial step in this planning process involved precise job site measurements. These measurements were crucial for determining the available workspace and ensuring the new bins fit within the designated area. Following this, we began drafting and creating detailed 2-D and 3-D CAD drawings of the proposed storage tanks. These visualizations allowed us to evaluate how the tanks would be positioned within the space and identify potential issues, such as misalignment with existing structures or interference with other equipment like catwalks and turn head pipes. Additionally, precise measurements helped us assess the angles of existing equipment, revealing that the existing elevator leg needed to be raised by 17 feet to accommodate the new bins.
Planning also required a thorough analysis of the new equipment’s operational requirements. We needed to determine each component’s capacity, including how many tons per hour the loading and unloading conveyors could handle, the speed at which feed trucks were operating, and the appropriate size for turn head piping to ensure a smooth flow of ingredients. These calculations were just a few of the many considerations to address before the project could commence.
Once all the proper calculations and measurements were set in the plans, commencement on the job site could begin. The chosen location for the new bins was strategically selected to use previously unused space at the feed mill. To prepare for their installation, a concrete foundation was necessary. Before pouring the foundation, multiple auger pilings were driven 20 feet into the ground. Auger pilings, or auger-cast piles, are deep foundation elements that play a crucial role in the construction of stable structures. They are created by drilling a hole into the ground with a large screw-like auger and filling it with concrete and reinforcing steel. Their primary function is to transfer loads to deeper, more stable soil or rock layers, ensuring the structural integrity of the bins.
After the stable foundation was completed, we could build upwards with confidence, allowing us to make the most of the available space. For the bins, we chose Chief Agri Lemanco modular storage bins because of their flexibility to customize their size. This was a key selection for the project, as it allows us to fully utilize the limited footprint and maximize the storage potential for the commodities. The bins are a big upgrade from the ten round bins that were previously used for storing commodities.
The installed bins stand an impressive 94 feet tall, extend 50 feet long, and span 20 feet wide. This expansive structure features 13 separate compartments designed to accommodate a diverse range of commodities. This configuration allows for organized and efficient storage, catering to the mill’s diverse ingredient requirements. Following the installation of the bins, we had to remove ten round bins from the back side of the feed mill. These older bins, which the Lemanco modular bins replaced, occupied more space than desired and were no longer efficient. Removing them was a clear answer, as the new bins would significantly outperform them. It also opened up the area for future expansions at the feed mill. Aside from removing the ten round tanks, additional equipment was added, including further conveying systems, turn heads, transitions, and more. Our involvement in this project went beyond mere installation. The Top Bead team took on the full scope of the project, including the management of installation and equipment setup, as well as providing crane services to erect the bins. We also handled all material logistics to ensure a smooth and efficient process from start to finish. Every aspect of the project was meticulously designed and executed in-house, reflecting our commitment to quality and attention to detail.
The results of our efforts are evident in the transformation of the space. The pictures show a before-and-after comparison of the installation area, showcasing the significant impact of our work. This project not only enhanced the feed mill’s storage capabilities but also demonstrated our ability to deliver complex solutions tailored to our client’s specific needs.
