Grain processing becomes automated

CEDAR RAPIDS - Grain processing, an industry in the Corridor since 1873, provides 12,000 direct and indirect jobs.

Whether for food or bioproducts, grain processing employs a diverse mix of people, from production workers to research scientists. The average annual salary is $85,000, which does not include the electricians, millwrights, pipe fitters and plumbers who work for third-party contractors.

Gone are the days of hand-packing cereal in cardboard tubes or climbing to the top of grain silos to close valves. Automation and process-control systems play a dominant role at Archer Daniels Midland, Cargill, Diamond V Mills, General Mills, Genencor, Heinz, JRS Pharma, J. Rettenmaier, Penford, Quaker Oats, Ralston Foods and SunOpta, all of which are either based or have plants in Cedar Rapids.

Paul Kerr, manager of Cargill's soybean processing plants at 1103 12th Ave. SW and 410 C Ave. NE, said computers control all aspects of manufacturing and packaging.

“The type of equipment and the technology that surrounds it is significantly different from what it was 30 years ago,” Kerr said. “The jobs that we have are more technology-based and involve working with computer screens.

“I can see how every aspect of the plant is running by checking my computer screen. Some of us have the capability of accessing that data from our homes, something that wasn't possible just five years ago.”

Cargill employs about 90 people at the 12th Avenue SW plant, which makes soybean meal and soybean oil for human food production. Another 40 employees work at the C Avenue NE plant, which supplies animal feed manufacturers.

“We employed more people at each plant before about 2000, when we had employees walking around reading gauges every hour,” Kerr said. “Computers monitor all those functions and make adjustments automatically as needed to assure a consistent product for our customers.”

Kerr said many positions that once required physical strength to lift as much as 100 pounds have been replaced with technology. That has reduced the number of employees but has allowed women to work in many areas, he said.

Genencor, which makes enzymes used in detergents, ethanol and high fructose corn syrup, employs a work force of 114 at 1000 41st Avenue Dr. SW.

“We have process operators, lab

technicians and maintenance technicians,” said Kim Lorenz, director of human resources at Genencor. “In our engineering positions, we target people with chemical engineering and biochemical engineering backgrounds. Our new Applied Innovations Center employs Ph.D.-level candidates.”

Lorenz said a good solid mechanical aptitude, troubleshooting and analytical skills and the ability to work with others in a team are essential for candidates. Many of the process operators have two- or four-year degrees.

“Experience with computers is probably the most important for us,” she said. “It's knowing how to analyze the data and how to operate the automation system to control the process.”

Tim Kortemeyer, president of Penford Products, said the producer of industrial starches and ethanol employs a wide range of employees.

“We have process operators and maintenance technicians that make around $20 per hour, or about $35 an hour if you include benefits,” Kortemeyer said. “We have people with engineering degrees who supervise plant operations. At the management level, you will find people with a minimum of a bachelor of science degree, and our research and development area has people with Ph.D.s.

“In the finance area, we have people with a master's degree in business administration.”

Kortemeyer said automation also plays a critical role at Penford.

“We have people working in a control room that looks like something out of NASA,” he said.

Kirkwood Community College is an industry training resource for potential new employees and existing workers. Dennis Owen, Kirkwood professor of industrial maintenance and heating, ventilating and air-conditioning, said many people who keep the automation equipment running at grain processing plants were trained at Kirkwood.

“We have quite a few of our past graduates working at ADM Corn Sweetener,” Owen said. “Our grads go to work anywhere that industrial equipment needs to be maintained - anything from a basic motor all the way up to a sophisticated computerized automation system.”

Owen said the demand for industrial maintenance technicians is expected to grow dramatically in coming years.

“There's a lot of baby boomers who will be retiring,” he said. “3M put on a presentation hoping to get some of our second-year students to go to Omaha to take a look its facilities. The company was offering excellent pay and benefits.

“No one went up there because they knew there were going to be jobs available here in Iowa.”