Breaking Down Hot Loading Systems: Key Benefits and Types of Systems

A hot loading system refers to the ability to combine crop protection products with a carrier product that is loaded at the facility and can be transferred directly into a tender truck or sprayer without the need for in field mixing. Ultimately, leaving the facility with all active ingredients combined in a single tank. An alternative to mixing chemistry in the field before spraying, hot loading systems provide numerous benefits to the facility, sprayer or tender operators, and ultimately to the farmers themselves.

1.         Reduced Downtime and Increased Efficiency

2.         Reduced Product Shrink and Increased Blend Accuracy

3.         Safety and Environmental Protection

4.         Product Traceability

Reduced Downtime & Increased Efficiency

When the product is mixed at the facility rather than in the field, there is a significant reduction in downtime for the sprayer operator and a faster turnaround time for the individual running chemicals to the field. Without the need to check formulas and ensure the blend is correct in the field, hot loading systems enable continuous operation during the busy application season, resulting in more acres covered in less time.

Reduced Product Shrink and Increased Blend Accuracy

The meters, sensors, and programmable variable frequency drives (VFDs) utilized in the agronomy facility itself are far more accurate than a transfer pump or what is available to someone mixing in the field. When products are hot loaded at a facility, there is reduced product shrink and increased blend accuracy resulting in more accurate inventory records and billing for both the facility and farmers.

Safety and Environmental Protection

Hot loading systems significantly enhance operator safety by eliminating the need to handle multiple chemicals outside an environmentally controlled facility. In the field, wind and other external factors can impact the safety of individuals handling these chemicals. Additionally, hot loading significantly reduces the chances of a spill or overfill, which increases environmental protection as well.

Product Traceability

Keeping product mixing within a facility allows the facility’s automation controls to capture real-time, accurate data on which ingredients are added to which mix. In the event the data needs to be provided to an external source, the system can display exactly which product and the quantity injected into that load. This enhanced level of product traceability is achieved through an automated hot loading system, rather than relying on manual methods.

There are two main types of hot loading systems: direct injection and a weigh tank. Below, we’ve given a brief explanation of each.

Direct Injection	Weigh Tank
Each chemistry is measured on its device and is piped directly to the injection point.  This allows the automation system to run multiple products simultaneously, as each has its individual measuring device and pipe. This is a very efficient hot loading system and significantly reduces loading times and increases product accuracy.	Each chemistry is directed into a centralized weigh tank at a facility. This method offers greater versatility and flexibility, as it allows for the addition of products not already piped within the facility. For example, hand-adds in individual jugs. This versatility does come with slower load times, as all products pass one at a time through a single measuring device after entering the weigh tank.
Click to Expand HMI Screen for Better Viewing	Click to Expand HMI Screen for Better Viewing

For more information on hot loading systems and automation at your agronomy facility, contact our team at www.easy-automation.com or 507-728-8214. Our team would be happy to discuss what might work best at your facility and how we can partner to make that happen.