How Ingelam Transformed an Artisanal Process into an Automated System, Doubling Daily Production and Empowering Human Talent.

The Challenge

A balanced animal feed production plant for self-supply faced a structural problem in its operations:

• Ingredient dosing was done manually, controlled using dials and weight indicators.
  
  
• Operators calculated quantities “by eye,” leading to errors and inconsistencies in mixtures.
  
  
• Workdays were long and exhausting, with poor traceability control and high levels of waste.
  
  
• The client sought to increase production capacity without building a new line, while maintaining strict quality control over their formulas.

Ingelam’s Solution

Ingelam’s engineering team designed and implemented a comprehensive solution to fully automate the dosing process, utilizing the existing equipment as a foundation.

The strategy combined:

• Complete automation of scales and valves, eliminating manual intervention in dosing.
  
  
• Integration of sensors, controllers, and customized electrical panels, tailored to the plant’s infrastructure.
  
  
• Development of proprietary control algorithms based on weighing precision, automatic sequencing, and operational safety.
  
  
• Technical training for personnel to ensure adoption of the new technology and efficient use of the system.

All implementation was carried out without halting production, prioritizing operational continuity.

The Results

The change was immediate and transformative:

• Daily production doubled without the need for a new production line.
  
  
• Mixing and dosing times reduced from several hours to minutes.
  
  
• Full process traceability achieved, eliminating human errors.
  
  
• Energy consumption and waste decreased, boosting operational profitability.

Moreover, the human team evolved alongside the technology: operators transitioned from repetitive manual tasks to supervisory and control roles, strengthening their technical skills.

The Voice of the Project

“When the plant began operating automatically and the operators saw the system handling everything on its own, they realized that automation wasn’t replacing them—it was empowering them.”

— Jefferson Bedoya Hoyos, Technical Manager, Ingelam.

Lessons Learned

This project demonstrated that automation doesn’t always mean investing more, but rather investing smarter.
The key lies in leveraging existing infrastructure and enhancing it with intelligent engineering.

Ingelam reaffirmed its philosophy:

“Every project is an opportunity to optimize, not replace.”

Mirando hacia el futuro

La experiencia en esta planta marcó el inicio de una nueva generación de proyectos de automatización modular y escalable.
Hoy, esta misma metodología se aplica en otras plantas de autoconsumo y agroindustria, donde la eficiencia y la sostenibilidad son prioridad.

Looking Ahead

The experience at this plant marked the beginning of a new generation of modular and scalable automation projects.
Today, this same methodology is being applied in other self-supply plants and agribusiness facilities, where efficiency and sustainability are top priorities.

Final CTA

Is your plant still relying on manual processes or lacking precise control over production?
With Ingelam, you can automate progressively without halting operations and achieve a tangible return on investment from day one.

👉 Discover more at ingelam.com.co
Ingelam: Engineering that transforms work into productivity.