moisture control
Greg in Ontario
Greg has been using Dryer Master since 1993, so that is a total of 25 years! In that time he has upgraded from his original DM150 model and added a second system. He now runs his a new DM510 on his Zimmerman VT2541 tower dryer and his older DM500 on his Farm Fans CMS-1000H. He typically dries about 1.4 million bushels a year of corn and occasionally soybeans.
How much training was required to operate the Dryer Master?
4-6 hours initially, then some followup when we upgraded models.
How often do you calibrate your sensors?
Twice daily, unless there is a wide variation in wet test weight, then we check more often.
Have you contacted the Dryer Master Support Centre? What was your experience?
Yes, we upgraded one unit and replaced another. TechSupp was excellent at preparing us for the switch over and correcting the minor problems that cropped up.
Is there anything you would like to see improved in the Dryer Master?
There are read outs for inlet grain temp, outlet grain temp, and plenum temp, but not for grain temp (in the column). We have to go outside to the dryer
panel to view this.
DM Comment: This could be an option in the future. For now we have tried to keep the operation and installation as simple as possible and only gather information that will be used in the control calculations. The grain temps from the moisture sensor are used in the moisture reading calculations and the plenum temp is monitored so that the the control model can be immediately updated if the dryer operator changes their drying temp. The grain column temp is not used in the control calculations so it would only be provided for informational purposes.
Mark in Indiana
Mark is relatively new to Dryer Master. He has had his DM510 for two years now. He uses it to dry about 500,000 bushels of corn and wheat in his Delux dryer.
Why did you buy a Dryer Master in the first place.
It was recommended by my dealer.
Have you found a financial difference in your drying performance using Dryer Master? In what way?
The Dryer Master is a management tool. It saves money by not over drying or under drying the grain. This saves in minimizing grain shrink and moisture dock and it gives gas savings.
Is there anything you would like to see changed in the Dryer Master (new fe
atures?)
I’d like to see “suggested rates” in manual mode to show on DM Mobile. (DM Comment: Excellent idea. This is something we will be adding.)
Do you use DM-Mobile? If so how do you use it (phone/PC/home/at night?), how often do you use it?
DM Mobile is my favorite feature. I use it all day while in the combine and it is on when I go to bed, so I can wake during the night and check the dryer in bed. It is great peace of mind!
Chris in Illinois
Chris has a Grain Handler 2416 dryer that he uses to dry about 500,000 bushels of White and Yellow Food Grade Corn. He has had his DM510 for 2 years now. His DM510 is conveniently located right next to where he does his manual moisture tests.
Why did you buy a Dryer Master in the first place?
We bought the DM510 to automate and remotely control our Grain Handler 2416.
How often do you typically calibrate your outlet moisture sensor? And what is your calibration procedure?
During harvest we sample and calibrate every 1 to 1.5 hours. We press the sample button, run it through our Perten tester three times, average the results, and enter the moisture into the DM510.
Do you use DM-Mobile? If so how do you use it (phone/PC/home/at night?), how often do you use it?
Yes, I monitor the dryer via an IPad while in the combine during the day and use my IPhone at home after work. It is used all the time the dryer is running.
Trevor in North Dakota
Trevor dries less than 250,000 bushels annually of corn and wheat with his Grain Handler dryer. He has had his Dryer Master DM510 for three seasons now.
What had you heard about Dryer Master before you purchased one?
Advanced Grain Handling suggested a Dryer Master because that is what they had and really liked it. We wanted something that was smart phone capable and we are glad we got the Dryer Master.
Why did you buy a Dryer Master in the first place?
To be more productive… We couldn’t run 24 hours a day before the Dryer Master because we didn’t want to under dry or over dry.. with the Dryer Master we can run 24 hours a day which is huge to getting our crop off before the weather changes in North Dakota… Every day is crucial and we have to be able to get the crop off and dry it down!
How does the Dryer Master change the way that you dry, or alter your drying operations from
an operational perspective?
We decreased paying a guy to baby sit the dryer all day. With Dryer Master we can look at our phones when we are not by it. Semi drivers and always monitoring it when dumping their trucks. We dialed in our set point for our dryer and it comes out consistent throughout our desired moisture for storage.
Did anything surprise you about how your Dryer Master worked when you first used it?
It took awhile to get used to it and a lot of phone calls just to get everything set but now we are familiar with everything.
Have you found a financial difference in your drying performance using Dryer Master? In what
way?
Any kind of product that can give you a return on your investment is crucial in this business. This monitoring system pays for itself yearly in our eyes with the elevators being so aggressive on drying and shrink charges.
Brian in Indiana
Brian is a long time Dryer Master user, having used Dryer Master systems for over 25 years now. He dries over a million bushels a year of Non-GMO waxy corn and has a wealth of experience to share.
Brian recently updated his two DM500 systems to two new DM510 systems to go on his two Zimmerman grain dryers, one a AP4500 and the other a Zimmerman VT3026.
Why did you buy Dryer Masters in the first place?
We were looking for a way to take the guesswork out of drying. Because we are a long term storage facility with minimal outbound blending capabilities, we needed consistent moisture and quality going into storage. The Dryer Master has been able to take the peaks and valleys out of our moisture content.
How does the Dryer Master change the way that you dry, or alter your drying operations from an operational perspective?
We had to learn to let the Dryer Master do it’s job. I tell my operators that every adjustment they make when drying, is probably undermining what the Dryer Master has “planned”. We had to learn not to react to what was happening with outbound samples (unless it’s a long term trend)…for instance, if the outbound sample isn’t correct, that adjustment should’ve been made 2-3 hrs ago. We watch the hourly trend and trust that the DM knows what’s going in and what’s coming out and will adjust dryer speed accordingly to hit the average target moisture. Operators have to understand that the DM is always trying to average to the target…if corn is coming out a little dry for an hour, expect the dryer to speed up and you might see a little bit of wetter corn for an hour. My main advice to operators…”don’t over-react, let the DM d
o it’s job”.
What drying tips (if any) would you like to pass on to other dryer owners about how to get the most out of their dryer and/or their Dryer Master?
During harvest, we often can see a 5-10% spread in the moisture of inbound grain. While the Dryer Master can handle those ranges of moisture, we try to “help” it by making the inbound wet grain stream more consistent. We have 3 wet hopper tanks and will divide those into 3 moisture ranges. We then blend those grain streams to the dryer to get a more consistent moisture content on the inbound side of the dryer. This helps the Dryer Master by not making it “react” to those big swings. It also helps us narrow the range that it takes to get to our average outbound target moisture.
Have you fo
und a financial difference in your drying performance using Dryer Master? In what way?
Yes. Anytime we overdry corn or underdry corn and have to recirculate, we are not getting efficient use of our utilities expense or our drying assets. The Dryer Master minimizes those situations and helps us stay within a very narrow +/- range of our target moisture.
How often do you typically calibrate your outlet moisture sensor? And what is your calibration procedure?
We sample every 30-45 minutes while the dryers are running. We keep a log sheet comparing DM sample to Moisture Meter (Dickey-John) sample. If we have 3 samples in a row that are off more than .5% in the same direction…then we calibrate.
Aaron in Illinois
Aaron has a smaller 1610 Grain Handler dryer that he uses to dry about 200,000 bushels of oats and corn. He has now had his DM510 for 2 seasons and uses the Dryer Master moisture sensor chute with a rotary feed which helps provide a consistent flow of product past the outlet moisture sensor.
Why did you buy a Dryer Master in the first place?
I had not heard anything about Dryer Master but my bin dealer and the Grain Handler folks recommended it.
How does the Dryer Master change the way that you dry, or help your drying operations from an
operational perspective?
It allows me to be a little freer to do ot
her tasks.
How often do you typically calibrate your outlet moisture sensor?
All throughout the first day, then if it is staying close to the bench tester, just once a day.
How much difference does it make to have real time moisture information versus having to go out and take a sample?
A lot. I’m able to check the moisture of the dryer discharge no matter where I am.
Do you use DM-Mobile for remote access.
Yes, I use it on my smartphone all the time, day and night.
Brian in Pennsylvania
Brian dries about 250,000 bushels of corn and soybeans with his Grain Handler 1610 dryer. He has now had a Dryer Master DM510 for 3 seasons. In the photo of the DM510 panel, on the right there is a small black device. This is part of the remote wireless I/O setup option. This option simplifies installations where the DM510 panel is located at a far distance from the dryer, or where a conduit run would be difficult.
Why did you buy a Dryer Master in the first place?
It was recommended by the Dealer and Rep from Grain Handler
Did anything surprise you about how your Dryer Master worked when you first used it?
I was surprised how it could compensate for different input moisture after it had run long enough to build the data it needed. Compensates better for large input changes than any other controller I have used.
How often d
o you typically calibrate your outlet moisture sensor? And what is your calibration procedure? (Note: The photo is of the outlet sensor installation. Brian diverts a portion of the outlet flow to a pipe where the sensor is mounted. The product flow past the sensor is kept constant by the auger that returns the product to the main stream. )
Check / Calibrate several times daily especially if we changed varieties of corn. Also check before overnight. I recalibrate if its more than a couple tenths off. I push the calibrate button mounted near sensor and take a sample over about 20 to 30 seconds. Gives me enough grain to run two tests on my moisture tester. If both tests are close to the same, I average and recalibrate. If the tests are not close, I start over.
Ryan in Ontario
Ryan has been a Dryer Master user since 1999. The first Dryer Master installed was a DM500 model and it went in at their then only drying location. In 2009, with the construction of a new facility at a new location, two Dryer Master DM510s were added for their Dorssers dryer. (For those unfamiliar with the Dorssers dryer it is an Ontario made dryer that you can see at quite a few locations around Southern Ontario.) In Ryan’s case each Dryer Master controls 1/2 of the dryer and so you can have the two sides running at different speeds. Combined, Ryan dries around 750,000 bushels of corn a year.
Why did you buy a Dryer Master in the first place?
The ease of controlling the dryer and improving the output consistency for storage. We also liked the idea that you could run it in an automatic mode which allowed us to focus time on other areas of the business during harvest.
How does the Dryer Master change the way that you dry, or alter your drying operations from an operational perspective?
When operating the Dryer Master, patience is key. You have to have trust in the system to follow the targets that you set out to achieve. It allows you to focus on other areas of operations during the peak time and yet have faith that the targets will be met.
Did anything surprise you about how your Dryer Master worked when you first used it?
It takes a bit of time to have faith that the targets will be met. At the conclusion of the year, it is surprising how close the targets are met when the final report is generated. This goes to show that corrections are made throughout the drying season and in the end you achieve what you had set as a goal going into harvest.
What drying tips (if any) would you like to pass on to other dryer owners about how to get the most out of their dryer and/or their Dryer Master?
Patience is key, give the DM time to learn the characteristics of the grain and it will meet your requirements. Keep an eye on all the moisture pods for blockage as this can give false readings.
How often do you typically calibrate your outlet moisture sensor?
We calibrate quiet often and likely too much.Every half hour if we have issues. On average we likely calibrate every 1.5 hours. When things are busy every 2-4 hours. It is nice to be able to go to the screen and know that the physical product is accurate to what the reading is giving you.
Dryer Master Experiences: Anthony in Ohio
Anthony has 2 Dryer Master DM510 systems, the first of which he added in 2007. He runs them on his two Zimmerman dryers, drying about 1.5 million bushels/year of corn and soybeans. This year he will be adding the DM Mobile remote access functionality so that he can check on his dryers at any time from anywhere.
Why did you buy a Dryer Master in the first place?
We purchased DM because any of the factory controls we had tried just did not work. We spoke to a neighbor that was running a DM at the time and they were completely satisfied. The DM was money well spent and I would not run without.
How does the Dryer Master change the way that you dry, or help your drying operations from an operational perspective?
The DM allows me to be more available during harvest season. I do not have to babysit the dryers all day and night. I just have much more confidence in the DM sensors and don’t feel I have to check constantly.
How often do you calibrate the moisture sensors?
I try and calibrate every chance I get. It seems once the dryers have been running a while I have to calibrate less often. I try to check it every couple hours.
And what is your calibration procedure?
My sampling procedure is this, for the input sensor I take several samples from the leg that is feeding the dryer. I average the moistures and wait about 12 min and start the calibration on the DM.
For the output sensor I hit the green button and take small samples the entire time the light is flashing (30 seconds). I run that sample through the tester about 3 or 4 times and enter in the average moisture.
You run two dryers. How do you allocate product between the dryers?
Normally for the first half of harvest one dryer is drying corn and the other soybeans. When I have them both in corn If we are harvesting inconsistent moistures I try to keep one drying higher moisture and one in the lower. We then unload both dryers into the same bin to get some blending between both of them.
Have you found a financial difference in your drying performance using Dryer Master? In what way?
The DM system has saved us time and money. I have consistent moistures coming out of the bin, we are not over drying like we did with previous controls, and the system is user friendly.
Dryer Master Experiences: Jon in Ontario
Jon is relatively new to Dryer Master but he is great example of how moisture control is no longer just for big elevators, and how more and more it is making its way into smaller operations.
Jon has a DM510 system and has had it for 2 seasons now. He added it as a retrofit onto an MC dryer and dries about 300,000 bushels a year of corn and soybeans.
Why did you
buy a Dryer Master in the first place?
We had been having issues with the original controller, the dryer had to be babysat 24/7. With just myself looking after the elevator during harvest it became very necessary to find a controller that I could trust so that I could get some sleep and be functional the next day.
How does the Dryer Master change the way that you dry, or help your drying operations from an operational perspective?
It has given me a lot more confidence in my drying system which allows me focus on other parts of the system which need my attention during the course of the day. Once its up and running I check the calibration once in the morning and once more before I head to the house for the night. With the Dryer Master running I just don’t stress about my dryer anymore.
Did anything surprise you about how your Dryer Master worked when you first used it?
I thought it would be more complicated to run than it is. I was completely comfortable running the system within just a couple of hours. The over the phone support is great, everybody at Dryer Master seems to know the system like the back of their hand.
What drying tips (if any) would you like to pass on to other dryer owners about how to get the most out of their dryer and/or their Dryer Master?
Give the system time to react if you make changes to the settings. 1-1.5 hours depending on how fast the dryer is running. Too many changes in a short period of time will have you frustrated and chasing your tail. Once the Dryer Master is up and running it takes very little interaction to keep it going. Let it work and find something else to fuss over.
Have you found a financial difference in your drying performance using Dryer Master? In what way?
The biggest financial gain for us would be the accuracy that it can discharge grain at the correct moisture. We have noticed that when shipping grain out, our bins are much more even top to bottom, with no wild swings in moisture. Over and under drying used to cost us every year, now its pretty much a non issue.
Do you use DM Mobile? If so how do you use it (phone/PC/home/at night?)
Yes, definitely. This is a huge benefit to my operation. I use it throughout the day from my Iphone, and also at night from my Ipad or Iphone. I can wake up a couple times through the night, see whats happening and get back to sleep. It has made the harvest season mush easier to get through. My days run much smoother because I’m not completely exhausted from being up all night with the dryer.
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