Project spotlight: Iowa Corn Processors
For Iowa Corn Processors, a privately held dry milling company based in Glidden, Iowa, the decision to automate their packaging operation was a carefully considered, strategic investment. With a layout that demanded creative engineering solutions and ambitious goals around waste reduction, expanded operating potential, and enhanced monitorability, the project required more than just great equipment. It required a partner who could engineer a solution that truly fit. That partner was Premier Tech.
About the client
Iowa Corn Processors (ICP) is a privately held agricultural company rooted in the heart of the American Corn Belt. More than just a processing facility, ICP positions itself as a partner in sustainable agriculture, blending decades of corn milling expertise with cutting-edge technology to deliver products of unparalleled quality.
Located in Glidden, Iowa, ICP's state-of-the-art facility specializes in dry milling, transforming corn into premium, value-added ingredients, including degermed and debranned corn flour, cones, meal, and grits. Their diverse customer base spans food and beverage manufacturers, bakers, livestock farmers, feed product companies, and health-conscious consumers.
With a strong commitment to food safety, rigorous production protocols, and sustainable practices, ICP has built a reputation as an industry leader, ensuring every kernel processed contributes to high-quality, environmentally responsible products. .
The challenge: rising the bar on packaging
Despite their state-of-the-art milling capabilities, ICP's packaging operation was ready for the next level. The facility was relying on a semi-automatic bagging process requiring heavy manual intervention, from filling bags to hand-palletizing directly onto a stretch wrapper. This approach created real operational pain points:
- Product waste from inconsistent, manually controlled filling
- Labor-intensive operations, fueling a desire to automate for greater efficiency and workforce improvement
- Production bottlenecks slowing throughput and reliability
Making the leap to full automation required a carefully considered, strategic investment, paired with a layout that demanded creative engineering solutions. ICP's team even completed preparatory construction work ahead of equipment delivery, a proactive move that proved critical to keeping the project on schedule.
The goals
ICP came to Premier Tech with three clear objectives:
- Automate their packaging production to increase efficiency and reliability
- Reduce product waste through tighter process control
- Enhance monitorability of their operations — key performance indicators for quality and process control
The Premier Tech solution
Premier Tech designed and installed a complete, fully automated packaging line, engineered with a custom layout to maximize ICP's production floor.
The line includes the following equipment:
- CHRONOS BFL-1060 Open-mouth bagger
- CHRONOS BCH-1100 Bag closer
- CHRONOS ISC-1000 Bag seal inspection system
- CHRONOS RPL-4111 Robotic palletizer
- CHRONOS WCA-150 Series Pallet wrapper
This turnkey installation fully replaced the semi-automatic, labor-intensive process, representing a major technological leap for ICP's packaging operation.
Results & impact
Since commissioning, the new line has delivered meaningful improvements across ICP's operation:
- Increased production speed and throughput — a consistently faster and more reliable output than the previous manual process
- Improved product quality consistency — controlled filling and automated palletizing reduce variation and product loss
- Enhanced monitorability — fully aligned with ICP's commitment to process control.
- Reduced physical workload for team members — eliminating repetitive, labor-intensive manual palletizing tasks
- Delivered ahead of schedule — seamlessly commissioned with minimal disruption to ongoing operations
The client's voice
"Overall, I have been incredibly pleased with the quality and simplicity of the entire system, despite the highly technical automation involved. The installation, commissioning, training, and support teams have been unparalleled. They ensured a smooth, successful, and ahead-of-schedule implementation that did not go unnoticed. I am extremely pleased with the product and highly recommend Premier Tech to anyone looking for top-notch automated packing and/or palletizing solutions."
— Chris Giguere, President and CEO, Iowa Corn Processors
"The level of acceptance and ownership of the system by our operations team tells me all I need to know about the quality that Premier Tech provides. Would I buy that again? Yes."
— Michael Regier, Capital Projects Manager, Iowa Corn Processors
"The HMI design is fabulous — it is intuitive and consistent across equipment. Every single technician had a level of knowledge that was very impressive, and every single one of them had the ability to teach and explain to us very well."
— Hayes Charles, Plant Manager, Iowa Corn Processors
A partnership built on expertise
What made this project stand out wasn't just the technology, it was the approach. The Premier Tech team conducted two Factory Acceptance Tests (FATs) prior to delivery. Held in Montgomery, Alabama, and Rivière-du-Loup, Canada, these sessions gave ICP's operators hands-on familiarity with their new equipment before it even arrived at their facility. As Plant Manager Hayes Charles put it, the FAT process was "one of the most important factors that helped build our confidence in operating such an intimidating level of technology."
That same level of preparation and rigor carried through to installation. As Capital Projects Manager Michael Regier noted:
"The mechanical installation was impressive. It was very clear the team was prepared and organized, a testament to how well Premier Tech designs and tests the equipment and process prior to delivery."
Onsite training during installation and commissioning was equally praised, with ICP's crews picking up operations quickly thanks to the knowledge and teaching ability of Premier Tech's field technicians. The intuitive, consistent HMI design across all equipment further accelerated the learning curve.
From concept to handover, this project is a testament to what happens when engineering flexibility, responsive project management, and deeply knowledgeable field teams come together — helping a client who had worked toward this investment for years finally realize its full potential.
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