Since October 2011, Highland Growers of DeRidder, Louisiana has been running its business in a Monolithic Dome fertilizer blend plant. The dome has a diameter of 76 feet, a height of 36 feet and six bins.

Since October 2011, Highland Growers of DeRidder, Louisiana has been running its business in a Monolithic Dome fertilizer blend plant. The dome has a diameter of 76 feet, a height of 36 feet and six bins. (Keen Creations Photography)

Highland Growers: New Fertilizer Blend Plant

Freda Parker • Published • Monolithic Dome Fertilizer Blend Plants

Climate controlled dome eliminates waste, increases profits

When I asked Don Smith, manager of Highland Growers in DeRidder, Louisiana, how they like the dome they’ve been using since October 2011, he said, “We like it – very much.”

In particular, he added, "We like it because it’s climate controlled. It doesn’t get the moisture in there that our old, wood plant did.

“At the old plant, we used to have probably 15 to 20 ton of ruined fertilizer in a year. That’s a lot of money. We don’t have waste in the dome. It stays dry and cool.”

What’s not to like?

Highland Growers is a small, family-owned company. They have just six workers to handle the fertilizer.

According to Don, all six really like the dome. He said, "They love it. It’s lots easier to work in. There’s no moisture, so the fertilizer doesn’t get hard in the dome, like it used to. The workers don’t have to dig out hard fertilizer.

“This summer we had air conditioner trouble, but we had one unit going all summer, and it stayed about 85 degrees in the dome – and we’re bringing in a hot product and loading doors open at times.”

Going Monolithic

Highland Growers’ dome has a diameter of 76 feet, a height of 36 feet and six bins. It’s patterned after the fertilizer blend plant that Monolithic designed for El Dorado Chemical Company in Bryan, Texas.

Don said that he first learned about Monolithic from his friends at El Dorado. When Highland Growers heard about the significant, profitable difference a dome can make, they decided to go Monolithic. In fact, they hope to build more.

What makes the difference:

Climate Control – A Monolithic fertilizer blend plant is constructed of reinforced concrete, insulated and air conditioned. That prevents condensation and corrosion.

Special Additives – Monolithic uses a special mix of concrete, specifically designed to handle the chemistry of your stored product.

Energy Efficiency – The materials and process used in its construction turn the dome into a thermal battery that requires 50% to 75% less power than a same-size wood or metal structure.

Disaster Resistance – A Monolithic Dome can survive virtually anything Mother Nature can send your way, including tornadoes, hurricanes and earthquakes.

Fire Safety – The concrete shell will not burn. (After a disastrous fire, El Dorado Chemical decided on a Monolithic Dome for exactly that reason.)

Bulletproof and Secure – It’s a fact established with testing: A dome’s layers of reinforced concrete can resist the force of most bullets. That concrete also makes tampering and break-ins less likely.

Efficient Design – The dome’s round shape provides easy, time-saving access to every bin.

Strength and Durability – A Monolithic Dome can withstand the abuse of front loaders and heavy machinery. It has a lifetime measured in centuries.

Safe from Termites and Rot – The dome will not be eaten by bugs or rot.

Efficient Construction – The patented construction process Monolithic uses saves time and money.

Please watch, then contact us

We invite you to review a short, informative video about our blend plants. Please watch http://www.monolithic.com/stories/blend-plant-video and then contact us with your questions and concerns: [email protected] or 972-483-7423.

This project included the installation of two elevators. These elevators give Higland Growers the flexibility to move material into multiple locations and from multiple sources. The dome can easily support the weight of all of the interior and exterior equipment.

This project included the installation of two elevators. These elevators give Higland Growers the flexibility to move material into multiple locations and from multiple sources. The dome can easily support the weight of all of the interior and exterior equipment. (Keen Creations Photography)

Highland Growers, a small, family-owned operation with just six workers to handle the fertilizer, is very happy with its new plant. Manager Don Smith said that they especially like it “because it’s climate controlled. It doesn’t get the moisture in there that our old, wood plant did.”

Highland Growers, a small, family-owned operation with just six workers to handle the fertilizer, is very happy with its new plant. Manager Don Smith said that they especially like it “because it’s climate controlled. It doesn’t get the moisture in there that our old, wood plant did.” (Keen Creations Photography)

This Monolithic Dome fertilizer blend plant is equipped with an elevator. A control panel sits close to the elevator base.

This Monolithic Dome fertilizer blend plant is equipped with an elevator. A control panel sits close to the elevator base. (Keen Creations Photography)

Elevator with the truck load out leg – The dome has the ability to safely hold the entire equipment load. Mounting to the dome is simple and permanent.

Elevator with the truck load out leg – The dome has the ability to safely hold the entire equipment load. Mounting to the dome is simple and permanent. (Keen Creations Photography)

In this side view of the dome, the two elevators can be seen in the background.

In this side view of the dome, the two elevators can be seen in the background. (Keen Creations Photography)

A Monolithic Dome makes an ideal fertilizer blend plant. It is moisture-controlled, energy-efficient, disaster-resistant, durable and easily maintained.

A Monolithic Dome makes an ideal fertilizer blend plant. It is moisture-controlled, energy-efficient, disaster-resistant, durable and easily maintained. (Keen Creations Photography)

The plant is equipped with a weigh hopper. Products are brought from multiple bins, dumped into the weigh hopper and measured before they are mixed.

The plant is equipped with a weigh hopper. Products are brought from multiple bins, dumped into the weigh hopper and measured before they are mixed. (Keen Creations Photography)

Highland Growers’ blend plant is equipped with state-of-the-art electrical components.

Highland Growers’ blend plant is equipped with state-of-the-art electrical components. (Keen Creations Photography)

Pictured here is the rotating distribution conveyor. The top conveyor brings material from the outside elevators, drops it into the rotating conveyor, then delivers it to a specified bin.

Pictured here is the rotating distribution conveyor. The top conveyor brings material from the outside elevators, drops it into the rotating conveyor, then delivers it to a specified bin. (Keen Creations Photography)

Bin walls are sprayed in place with a special mixture of chemical- resistant concrete. These bins are super-strong and will last decades longer than their wooden counterparts.

Bin walls are sprayed in place with a special mixture of chemical- resistant concrete. These bins are super-strong and will last decades longer than their wooden counterparts. (Keen Creations Photography)

Catwalks surround the upper portion of the bin walls. They provide access to two important areas: an area to service the conveyor and an area to minitor the levels of the bins.

Catwalks surround the upper portion of the bin walls. They provide access to two important areas: an area to service the conveyor and an area to minitor the levels of the bins. (Keen Creations Photography)

Special bin doors were created to allow front loaders to access the material, while preventing spillage into the central area. The bin doors can slide up and out of the way once the level of material has fallen below a certain point. This allows the loader to drive into the bin and get the balance of the material.

Special bin doors were created to allow front loaders to access the material, while preventing spillage into the central area. The bin doors can slide up and out of the way once the level of material has fallen below a certain point. This allows the loader to drive into the bin and get the balance of the material. (Keen Creations Photography)

This front-end loader moves material from each bin into the weigh hopper. Once the material is loaded, it’s taken to a mixer and put onto a truck.

This front-end loader moves material from each bin into the weigh hopper. Once the material is loaded, it’s taken to a mixer and put onto a truck. (Keen Creations Photography)

This is a bagging station where material can be brought directly from the mixing drum and put into bags.

This is a bagging station where material can be brought directly from the mixing drum and put into bags. (Keen Creations Photography)

The plant uses thousands of bags during its bagging operation.

The plant uses thousands of bags during its bagging operation. (Keen Creations Photography)

Creating mounting points on domes is not a problem. The dome is designed and built to hold enormous loads at any given point. Penetrations are also easily created and sealed.

Creating mounting points on domes is not a problem. The dome is designed and built to hold enormous loads at any given point. Penetrations are also easily created and sealed. (Keen Creations Photography)

Monolithic and South Industries completed a turnkey job for Highland Growers with excellent results. We worked hand-in-hand with Highland Growers and shared resources and expertise to create a world-class fertilizer blend plant.

Monolithic and South Industries completed a turnkey job for Highland Growers with excellent results. We worked hand-in-hand with Highland Growers and shared resources and expertise to create a world-class fertilizer blend plant. (Keen Creations Photography)