How Automation is Transforming Local Feed Mills

In the world of animal feed production, change has been slow but the pressure to modernize is mounting. For small-scale feed mills serving local farming communities, traditional manual bagging systems are no longer keeping pace with rising demand, labor shortages, and evolving customer expectations. These outdated methods not only limit throughput but also place a heavy physical burden on already lean teams.

Understanding how feed bagging has evolved – from manual scooping to fully automated systems – can help producers make informed decisions about the future of their operations. In this post, we’ll walk through the history of feed bagging technology, explore the limitations of legacy systems, and highlight how automation has become a game-changer for small-scale producers.

An Abridged History of Animal Feed Bagging Systems

Manual Bagging in Traditional Feed Operations

Manual feed bagging originally involved workers scooping or shoveling feed into bags using simple scales or estimated measures. While this approach required minimal capital investment, it relied heavily on the dexterity and accuracy of the operators. Miscalculations and spillage were common, especially when handling large volumes by hand.

Beyond inefficiency, manual bagging took a significant physical toll on laborers. Repetitive motions, heavy lifting, and long hours of standing often led to muscle strain and workplace injuries. Production speed was inherently limited by worker stamina, slowing throughput during peak demand periods.

Transitioning Toward Mechanized Approaches

As demand grew, early mechanized systems emerged to ease the burden. These included motorized augers and automated sealers that improved speed and accuracy in specific stages like weighing and sealing. However, these systems still required workers to manually position bags and monitor machine functions closely.

While mechanization was a step forward, it didn’t eliminate the need for constant human oversight. Frequent pauses to resolve clogs or misalignments meant that many producers began to see technology as a necessary investment, not just for efficiency, but for sustainability.

The Role of Automation in Modern Feed Bagging

Today’s fully automated systems integrate every step of the bagging process from feed measurement and bag formation to sealing and labeling. High-precision load cells ensure accurate quantities, while automated sealers deliver consistent closures that preserve product quality and reduce waste.

Automation also brings speed and consistency that manual systems simply can’t match. Machines can process a continuous stream of feed at high rates, helping producers meet demand without overburdening their teams. Uniform bag weights and reliable sealing also support compliance with industry standards and customer expectations.

About BW Flexible Systems

BW Flexible Systems helps animal feed producers modernize their operations with automated and semi-automated bag filling and palletizing solutions. Our Thiele bag filling and SYMACH palletizing solutions are known for being compact, cost-effective and easy to use. We offer training, service and a lifetime of support for every solution sold. Our portfolio includes:

• Thiele Swinger Bag Filling System: The Thiele Swinger is a compact, semi- or fully-automated bag filling system that helps small feed mills transition from manual to efficient, scalable operations. With intuitive controls, quick changeovers, and a low-profile design, it’s ideal for producers with limited space and growing demand.
• Thiele OmniStar Bag Filling Machine: Built for speed and precision, the Thiele OmniStar fills up to 20 mid-to-large bags per minute while minimizing spillage and downtime. Its smart diagnostics, automatic reject system, and barcode-driven changeovers make it a powerful solution for producers ready to scale.
• Thiele 6128 Gross Weigh Scale: The Thiele 6128 delivers accurate, consistent weighing with a two-stage system and automatic compensation to ensure every bag meets your standards. It’s fast, easy to operate, and integrates seamlessly with BWFS bagging systems for a streamlined workflow.
• SYMACH Palletizing Solutions: SYMACH palletizers come in a variety of speeds and footprints, offering feed producers a variety of options for automating their palletizing.

Learn More

Did you find this content useful? To discover more insights, tools, and solutions tailored for animal feed producers, visit our Animal Feed Packaging Solutions page.