Modernization in the Grain Industry

Telematics and Camera Technology in Transportation

CHS, which operates a fleet of 3,600 commercial motor vehicles, has begun integrating telematics and forward-facing camera technology into its fleet. Telematics help ensure compliance with hours-of-service regulations and promote safe-driving practices by monitoring seatbelt use and other behaviors.

The company’s approach involves starting with a small-scale implementation to assess costs and benefits before broader adoption. Initially focusing on high-risk units like hazmat and energy fleets, the strategy allowed for a gradual rollout.

“It has become part of the cost of doing business. If we’re going to drive our fleet, we have to bake in that cost,” said Surdick.

Cameras equipped with artificial intelligence (AI) can detect unsafe behaviors, such as texting while driving, and alert drivers in real-time, encouraging them to self-correct and adhere to safety protocols.

“It can detect if there are signs of drowsiness, and it helps with your DOT score. If you get moving violations, the DOT maintains a score of you, and if it gets high enough, you’re at a higher likelihood of them coming in and doing full-blown audits on your logs, maintenance records on your vehicles, etc.,” said Eardley.

Implementation of in-cab camera technology has sparked debate within companies, centering on drivers’ concerns about privacy and the perception of being constantly monitored. “There needs to be consistency in responsibilities for each role and how that data will be managed. Have a policy or some kind of guidance on how the camera technology will be used within your organization before you just start putting up cameras in the cab,” said Surdick.

One strategy in mitigating resistance has been leveraging testimonials from other drivers who have experienced the benefits of the technology firsthand. Transparent communication with drivers is important to explain how the system operates and its intended purpose.

“The biggest point of push-back is the feeling that drivers are being watched,” said Surdick. “However, the technology is designed to record only during specific events such as sudden swerves or abrupt braking. These recordings are then transmitted to supervisors or safety contacts, alleviating fears of constant surveillance. This targeted approach aims to capture actionable incidents rather than continuous monitoring, which helps to build trust among drivers.”

“On probably three or four occasions now, having that camera available in the event of an incident or an accident has paid huge dividends for Scoular, especially with law enforcement, where we’ve been able to provide a tape and a video of that accident occurring when the other driver who is completely responsible won’t claim responsibility,” said Morris.

When selecting technology platforms, it’s essential to thoroughly assess their full capabilities beyond just cameras. “The goal is to have a one-stop shop where everything is integrated, allowing users to manage multiple functions from a single platform rather than switching between different systems,” said Surdick.

Evaluate what each platform offers, including features such as tablet technology, maintenance programs, and inspection systems. “The biggest oversight when we first implemented analytics in truck cabs was not making it user friendly for drivers, especially older ones who faced challenges with the technology,” said Morris.

Visibility Measures in Transportation

Enhanced light bars on the backs of CHS trucks are part of updated visibility measures. These light bars pulsate to signal impending stops to provide heightened awareness for trailing vehicles and have reportedly already resulted in a marked reduction in rear-end collisions.

CHS has also equipped bobtail trucks – used for delivering propane to residential customers – with advanced safety features such as blind spot-warning sensors and parking assist technology. For example, the sensors discovered a small child was underneath a vehicle before it was set in motion.

Enhancing Safety with Advanced Monitoring and Maintenance Systems

Hazard monitoring systems have been a staple in grain facilities for years but are now seeing significant advancements. Modern systems can be used on equipment, such as dust collectors, drag conveyors, and bucket elevators.

“ADM’s goal is to progress toward a more sophisticated approach, where we not only test the sensors but also check the health of the logic solver and the electronics, enhancing the reliability and functionality of our systems,” said Eardley.

Hazard monitoring systems can now be linked with computerized maintenance management systems (CMMS), allowing for more precise and effective monitoring and maintenance schedules, and enabling facilities to predict and prevent equipment failures more accurately. For example, using sensors with long battery life and remote monitoring capabilities ensures continuous operation and reduces the need for manual inspections, which can be dangerous and time consuming.

“We have testing devices now that allow us to simulate or actually test a temperature sensor, ensuring that the alarm system functions and the interlock operates correctly, which marks a significant improvement from earlier methods,” said Eardley.

ADM has expanded its safety measures for bucket elevators to comply with OSHA regulations as part of a long-term, five-year program, rather than an immediate or unrestricted investment, incorporating additional sensors like plug and flow detection. “Initially, there was lukewarm reception to expanding our hazard monitoring systems, but over time, industry incidents and personnel changes led to a gradual acceptance of the need for enhanced protection,” said Eardley.

Robotic and Autonomous Systems

Twenty years ago, the introduction of a robotic arm for packaging in a grain facility was groundbreaking, efficiently packing pallets without any workplace injuries. Today, the industry is exploring even more advanced technologies.

According to Morris, Scoular is experimenting with remote-controlled locomotive systems, which allow workers to operate rail-moving equipment from a safe distance, reducing the risk of injuries associated with manual operations.

“We recognized a pretty serious hazard where our fall protection systems just weren’t large enough. It meant that we could load a car, seal it, but then have to kick it out and have someone climb it again without fall protection to meet end user expectations. We’ve spent a lot in the past year expanding our existing fall protection systems to ensure employees remain protected at all times when they’re on top of rail cars,” said Morris.

Moreover, the company is investigating autonomous rail car loading systems capable of performing tasks such as opening and closing rail car gates and lids, inspecting for contamination, and managing the loading process without human intervention.

“If we’re looking and pursuing autonomous or quasi-autonomous systems, that plays into a larger picture as far as cost efficiencies. There’s an initial investment, but you always have to work in the payoffs and paybacks,” said Morris.

Morris acknowledged the initial resistance to replacing human labor with machines due to concerns about job loss. However, by automating tasks that were traditionally performed manually, companies can ensure continuous operations even during the current labor shortages of skilled workers and minimize their exposure to hazardous conditions.

“We’re starting to institute these sonar systems at the corner of each barge, allowing us to get draft readings without having to go out onto the barge anymore, which minimizes water exposure for our folks,” added Eardley. “The superintendent at one location can just take their phone and see how full the barge is in real time, even when he’s on vacation, reducing the need for labor and increasing the efficiency and safety of loading operations.”