Manufacturing Process for a Meal Bin - Spirofeed

[Music] [Music] so Ty we've come out here out to Martin's Martin o' brin's farm you've supplied a Spyro feed been here for people Spyro feed is a name that's uh long immersed in the agricultural industry it's a name I've known a long time I suppose you recently got involved with it do you want to give a bit of background to to your own business y uh our background is uh Matlow Engineering in Malo where we do a lot of work in feed milling and grain handling and from that I'm in Partnership there with shames missal and from there we spy feed was located quite close to us and we purchased spy feed about 2 and a half years ago and as you said a long time in the industry was established in 1970 and very well regarded name and branded we're very happy to be associated with and to developed further so since we've taken over we've invested a lot in equipment in new kind of manufacturing processes and bringing improvements to a bin that was all already very well regarded right and say maybe to focus on this bin here what size is it that's a 33 ton bin that Martin has uh that's gray quarted sheet it's a Tams approved bin a Tams type bin uh with the coloring our bins are different to others and that we have a plastic coated sheet on top of a galvanized steel sheet um from a lifetime point of view it has very high corrosion rating and it also has very low maintenance in terms of repainting or anything like that it holds this color for a very long time okay so I suppose look prior to this being installed we I suppose we had the opportunity to go in and see the the the tank being made so we have footage from that I suppose back from a couple of months back so let's go and have a look at that footage now and uh see the whole process involved very good okay so Ty we're looking at Martin's bin here now uh it's on the flat yeah um could you describe how it's made or yeah what happens the bin itself the the start of the production process is the preparation of the flat sheets uh We've a punching a bashard punching machine which we invested in last year in our next Workshop we can look at that afterwards and we see the preparation of the sheets the steel components are all kept in stock they're pre-fabricated and galvanized all our seal components are fully galvanized so they're stored out in in the in our yard and in as are needed but the starting point is bringing the sheets in off the racking and assembling the bin here the guys you assemble on the flat the bin is assemble on the flat uh from our point of view we think it's a safer approach you can have more guys working in the bin at any one time and bringing on different components of it and from the point of view of lining everything up and putting on the legs uh we just feel it it works best for the facilities we have okay okay so how many days to make this bin here so that bin is probably four full days uh having all the components ready to go on the ground round man powerwise there's a couple of guys at it the first day or two and then it ramps up near the end where there's more guys on it cuz they're probably a day away from finishing this bin no so there's a few more guys going on it okay so as we see there there's a couple of the defense and the fill points been added that's right that's the stephanus is at there he's adding the fill pipe and the guys are preparing it here so that runs from the top down to the bottom maybe 5 ft from the the bottom of the ground yeah and we're looking at two side glasses then why is there two there there's two because more visibility on Watson side the B but on this one one of the features is the sight glasses on the far side of the bin as well so when Martin is looking to see his level what he's at he can see through and he'll be able to see daylight on the far side when he goes below a certain level so for this particular bin he'll have visibility on about 12 ton when it's above that Cy class he's got at least 12 to left in the B okay that's fine so let's go and have a look so the machine outside where start absolutely okay so Ty you made an investment here with a machine what is this doing for you here uh that's a Basher punching and uh slitting machine so what this does is prepares the sheets we load this machine with the steel sheets and it's pre-program the CNC machine with the whole patterns and the sheet sizes so when the machine is running as darl started it'll cut the sheet to the shape and punch it it was investment we did an overall capx last year of about 200 over 200,000 that machine was the biggest part of it it's replaced in very manual process in the past where we were doing manual cutting an all nibbling machine and uh manual punching so it's taken the pro process for preparing sheets from probably 4 hours down to less than an hour okay and we were using two guys for that job they've been reallocated to building bins and we V I know on fulltime sheet preparation okay so the the punch head itself is stationary is it and the sheet is moving that's right the the machine clamps the the sheet it pulls it into position and it moves it underneath the head of the machine so the Machine Head is stationary there's a tooling inside in that with seven different components and as it's going along it'll rotate and select the the tool it needs whether it's for punching the different size hole is punching or for the nibbling The Cutting function okay yeah and it's all hydraulically driven is it it's a hydraulic driven machine yeah yeah so it's it's a big investment but there's a big return in it yeah yeah we get more accurate sheets the sheets go together faster when they're assemblying the bin um we're well ahead of the guys in terms of having stuff on the shelf for the next bin that's ready and they can pick off from the warehouse and straight into production okay and less err resposible to halls and everything uh yeser the whole thing is just it's it's whatever it's programmed absolutely yeah there's no deviation between the sheet that's prepared versus what to be put together and it matches the sheets because the sheets overlap on the bin yeah okay and uh they'll match all the time C that machine and when they overlap is there a slight fold on that or not or do they are they lying flat on top of each other or uh we'll have a slight fold coming down yeah uh particularly along the core for for a bit of strength and a finish but we'll double we we have sealant inside the hole between each hole so if you can picture the line of holes we'll have a double layer of sealant coming down there for a a double protection from any moisture coming in or dust material coming out so will we have a look at what thanks darl what you had here before just just a bit of contrast this is a Nibbler so this machine has been decomissioned since and uh it was a very inventive way of handling the sheets before there was a jig created two guys loaded a sheet onto it the machine was running and they fed the the sheet through the machine and the nibbling head cut away the shape they wanted so a very practical machine very very useful for a long time but I suppose the new machine is far safer and you have far more accuracy so this machine is it's a it's a legacy at the moment to the old the old uh where bins were done in it's just pack there and every Hall had to be probably pre-marked was it pre uh we have another machine in the main hall for for punching the machine for the holes but here the the sheet itself was put up and the table that it was on moved around in a a set way that did the cuty for them okay so as we look here you you've three main colors am I right in saying that that's right we've the the Martin bin we saw side is a gray color Merlin gray we have Goose swing sorry we've also Goose swing gray if it's an option a lighter shade of gray Juniper green is probably the most common one around and then we have the galvanized color our sheets or ALU Inc which is a higher grade of material than Al than galvaniz typical galvaniz sheets but they're typically the tree gray green and galvaniz the green sheets are probably the most popular I'd say 60% of our bins are green we've probably 20% galvanized and the remaining 20 is gray but the gray is are growing growing a popularity would be far more gray than we would have a year ago and the price differential between galvaniz and the color about 10% 15% in the past it was greater but uh it's come back a little bit it's about 10 15% difference between the galvanized and the color sheets which is cheaper the galvanized yeah yeah theing sheet is a bit cheaper okay the green the colored ones the green and the gray they're the Tams approved bins so they're they're supported by Grant Tams TS GRS okay uh so that finished but they're not painted they're plastic coed sheet okay and we have a couple of suppliers of those uh they're predominantly made in South Korea uh the CED sheets but we keep a stock here and we've a reasonable couple of months stock ahead of us at any one time okay so Ty we're in the art here so you um repair bins as well as part of the business we do we do we repair bins or where there's a very old Bill a customer would ask us to dispose it for them so we'll do that uh we have two trucks for deliveries and we have two outsourced uh delivery support Vehicles where we use high ABS cranes for our larger business or if you have a tricky site where you have access issues and we'll use those guys for that work they local companies as well right and or we've over an acre of space and where we we store lot of our stuff here so these are all our our galvanized legs for the bins varying sizes and then we have different components around the a so a little bit chaotic at the moment we have a lot of bins back that will be probably sold as used bins in the summer months um but again we've plenty space for for storing bins and moving things around okay yeah and your Market typically it's it's it's obviously Ireland yeah it's island of Ireland like our biggest markets are probably monster South lster and South conect okay that's our main Market but we are finding we're getting more inquiries as we head up for the north as well and we're happy to to take those as well okay yeah so we're looking at um raw steel here is this for making braces correct that's right ber they come in uh black steel so the process here is we take them inside they're cut to the size we want punched and on an iron worker machine then out for galvanizing and back in and that's what we see behind us here the galvanized bracings ready for production yeah and the turnaround time is typically a week like we have a good enough relationship with our galvanizers and a couple of all relics here that's right yeah part of the cleanup yeah they've a lot of work done they have a lot of work done yeah they're I'd say they predate Spyro field by Longway yeah yeah yeah but replaced Now by some of the new machine that we've put in yeah yeah so T you're going to show us some of the other parts this is one of our fabrication areas and what we do here is a lot of our steel components or if we had to custom any part of a bin a lot of the times you'll have customers who want some different feature at the bottom of their bin depending on how they want to take the feed out we'll do all that Fabrication in house uh this is the area this this this container now is components ready to go for galvanizing so what are they for they are for adapters to the bottom of the bin so this is what connects the bin to the attachment for taking the feed out and we have different types of shoots we have a shoot for the customer who wants to fill a wheel barrel or a bucket or a bag and we have a longer shoot in for somebody who wants to use the front loader of the tractor to get under it so you he needs a bit more space a longer shoot so these are these adapter pieces they're fully fabricated here all prep all the preparation is done here are in the sister business Matlow engineering where we do lot of the cutting and then fully fabricated welded here and sent for galvanizing okay yeah so what what device is that there and what doing Dave is operating the sh a farmer at the moment so they're farming some of the profiles of those uh compressed pieces that we see here in the ground yeah so that's a hydraulic uh tool that's just forces the shape of the adapter ring okay and they are all rolls there so for pieces that we have to shape again for Rolling steel plate steel a small little roller but a a very useful tool inside the structure yeah very basic but very functional absolutely yeah yeah very basic some of these are components in more attachments again where you have somebody who wants to customized there been for a specific purpose and you'd see a lot of that in maybe P Tre houses or p K producers where they're looking at a lot of volume flowing through constantly a typical farmer might use the bin twice a day uh if and then the theary especially but some of those uses are constantly trickle feeding all the time okay yeah so some of the old gear that was that was involved before you invested in the big machine these these were all um created developed in house many years ago SP feed was started in 1972 and these machines probably came on stream a couple years after that so they've been here quite a while but again they're probably uh redundant now at the moment because of the punching machine but they're a good backup to have at the same time yeah so quite inventive and something that was made in house uh you don't see that happening in engineering shops anymore people are buying Machinery off the shelf now and but this did an awful lot of work for an awful long time yeah and very good work out of these machines but they're not something that'll ever be thrown out I'd say we' have to keep these for the um for The Visitor Center when it's done yeah yeah yeah yeah okay so we're looking at obviously a galin first yeah that's as well that's a completed Vin so this is a 12 ton bin that's ready to go to customer I think that's out for delivery in the next couple of days again the galvanized one would have been the most popular and only been for a long time then when the grants came in they needed to be colored so these are becoming less common but still a very good seller yeah uh this is our fill pipe so the feed truck arriv into the yard and they'll connect on here and they'll blow the feed into the bin with py glasses these are a unique feature on our bins that we brought in over a year ago they're long they're about a foot long maybe 3 in wide it gives the farmer a lot more visibility on what's inside in his beenin so he can tell when he needs to reorder the level he's at yeah bit more visibility yeah absolutely this one now is going into a dairy Dairy Farmer so that's suitable now ready for a flexi augur to be connected straight onto that okay and we'd have a good relationship with most of the with all of the feed the paror or the the feed system suppliers so our our bins are suitable to connect on to yeah all the main Inland yeah so what we want to do is when have a look inside Martin's been here just to see the internal but is it braced or what's it typically uh at this point it's probably not braced but it will be is it and if they're if they're still turning it it will be yeah inside it there's no bracing it's supported on the outside with steel rings that's where it's getting the string from that's where it's getting the string so they're heavy Channel iron legs they go almost halfways up the bin and then we have three sets of support Rings running all around okay and again they're they're rolled angle it's a bit dark in there but the inside of the bin the guys are still no uh up working inside it as they're tightening the balls so tightening the balls is still a very manual process um but this so have you somebody inside and outside when the balls to be in tight okay that's just the way it is that's just the way it is yeah it's um it's it's it's the only way to tighten them yeah how many bols are on a project like that don't on a bin like this has about 2 and half th000 balls nuts and washes right yeah so there's a lot there's a lot of handling are is there a rubber in on those washers on that or yes yeah they're NE Pro washers so they'll give a sealant again for moisture protection inside and outside or just wash on the outside only yeah yeah but then at all on all the joints we have a double seal going down there we do sealant and there's a double seeding going down here to minimize any moisture risk or dust dust uh aspiration okay any other type of feed bins you split are you doing the split bins we do split bins yeah we do we um we went the Y at the moment a double compartment bin we do them up to 20 ton sizes um they're quite a popular bin as well probably 5% of the bins we do would be split bins double compartment bins uh like our typical customers are dairy and Bee Farmers Peak and poultry producers they're the four main customers we have yeah um so like again there's a lot of spy feed bins out there been producing bins since 1972 and we've had some very loyal customers and now we're into the second generation of spy customers yes which is uh which is great to see and there great loyalty the brand but we we're putting a lot of effort into developing it and looking at new products at the moment bring them on online for for for the next generation of okay so how many people have you employed here we 14 employees in SPI yeah yeah great so that's we have guys like we've probably six guys who will be rotating between deliverying of bins and service and repair work and then the rest of the guys are work shop sales and admin okay yeah it's good good of employees it is yeah and a lot of the guys have' been here for all of their working career so there's a lot of knowledge inside in the place do you offer appr ships um not for a long time we haven't taken out prentices but we're we're open to it absolutely yeah yeah we get guys in here and work experience from local schools a couple times a year and um they all seem to particularly the guys from the farming background they get a good feel for how the Bin's made and have an interest in it yeah but yeah we're we're very much open to someone who's interested in coming in yeah very good great so Ty the delivery of a of a tank and um could you we have some footage of this as well when the when the meal bin was been delivered here could you describe said the process typically once the order is place we agree a delivery date with the customer and we provide them with information as to the size of the base they require depending on the size of the bin so once everything is agreed and ready the day of delivery we'll arrive out we have two methods of delivery we have our trucks which are tipping and then for more Awkward access sites we'll have a truck with a high AB where we can lift the bin in position then our guys here can Bolt the bin secure it and that process takes a couple of hours and once they finished that the bin is ready for filling in this case Martin fitted the automatic feeders so that was probably another step in the process after that okay so let's walk a bit closer here so to the to the bin say the base what what depth of concrete typically are you looking for there's 250 mm of concrete in that yeah reinforced or just yeah reinforced okay right and the base would want to be in position maybe two weeks before we stand the bin up on top of it right okay so in terms of what was fac here say what's your role in this is this ear's or is the more Dairy Masters aspect here that's Dairy Master feeder uh that's a stainless steel box that attaches onto our bin so we have a standard fitting at the bottom of the bin to suit to suit their their feeders um they come to sight then you see on the side of there's a useful bag off shoot for the day Martin want to take a bucket of nuts out of that separate to go through the feeding system okay and so you can rotate this here I suppose with your arrangement to suit any angle that's right it's a circular adapter so they can swivel to the angle they want okay and so what size auger is that coming off here that looks like a 4 inch auger yeah and say braing is that your bracing then coming off or is that more da Master that's all da Master yeah okay yeah so let's follow the line in then to the Parlor so I suppose this Martin has two lines coming in from from two bins yeah he's used his he Martin reused his older bin put in position he has two feeds coming in to a hopper inside close to the rotary okay which we see here yeah and here's the option then to fill from both back into the rot yeah and so typically that that whole responsibility is is the the feeder or the the making machines fire yeah usually and we'll work closely with them then to to position the bin in terms of clearance that they'll require require from the ground to the bottom of the bin that they're minimizing some of the angles coming straight into the parder okay yeah that's fine and so T in terms of say an investment in bins and stuff like that it's fair to say like a bin will last a a long time it's you know in terms of investment it's it's a good investment for people I suppose in terms of what they can get out of it I would say so it's um relative to most other purchases on Farm as a capital spend they're very good value the average life of a bin is anything from 20 to 25 years if they're looked after their cost of ownership is very low after the first day there's no changing of Parts the only kind of Maintenance you need is to do an annual cleaning and we recommend strongly that that happens where somebody looks into their bin it cleans out any material that might be built up inside in it just to make sure the stuff is Flowing all the time so from that point of view I think they're very good value they're the best means of hygienic feed storage you're dispensing with bags there's not disposing of plastic um you're buying feed probably better when you're buying it bulk and also from the point of view of verment control they're probably the best solution for feed okay and you you offer a repair service as well is that right we do yeah that happens from time to time where you might have new shoots to be replaced uh we might repl very old bins you might have some uh corroded panels it might have to replace on a core so we can provide that service as well okay so the role of Tams then say Tams is diminished in terms of grants for people yes you know what's the benefit of that for people or what what's the reality of it financially bins bins are covered uh in Tams 3 yeah so and there's been an increase in the award level of grants for them which is quite generous so what we're seeing is that guys who are playing at the moment are probably in the running for a grant of maybe a minimum around 18,00 EUR for an entry level bin right so they're very good value when you weigh up the grant uh aspect of the contribution okay and I suppose a point that we like to focus on as well this Farm I suppose it's very well located here factory inside in malow that's right and again it's the dairy sector again in rural Ireland giving jobs inside mow supporting the business well SP feed started in mow in 1970 yeah so it's the oldest manufacturer of feed bins in Ireland yeah and that's something that we're very proud to continue since our uh takeover uh We've retained all the staff we had that were there long serving guys some of whom are farmers so of a very good understanding of what's what's required they've a lot of input in the changes we make to bins and new designs or new developments and we're always kind of developing new products or new features so our own team are very strong in that regard so we're very happy to have them but in terms of location cork is very good it's the heart of the dairy sector in Ireland and from the point of view of Melo it's a great gateway to the rest of the country yeah and we cover right up to the northern counties for supplying of our bins and look at the end of the day jobs created you know people are making a living from from it that's right we' and it's all coming from the dairy sector which is getting a lot of negative press at the minute but again Royal Ireland it's a huge beneficiary of it whatever people might say absolutely and uh Spyro feed and mat FL yeah we're very proud to be a part of it and being well by extension link to the agre food sector like Dairy is probably something that the end user doesn't suffer too much when mid price is strong but there's a massive benefit to the whole economy when mid price is strong farmers are as business people very good at reinvesting in their businesses and developing and this is a prime example of here when you see what Martin and his family have done yeah so we look continued success in Sp feed and hope it'll go on for another 40 to 50 years I suppose at this stage please God and likewise to Grass birthday okay thank very much thank you thank [Music]

Channel: Grasstec Group

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Id: hZzryA_W1S4

Length: 22min 55sec (1375 seconds)

Published: Sun Apr 28 2024