Coalmont automated two manual chip truck unloading stations at Georgia-Pacific Monticello into a sophisticated driver-operated automated system. The previous operation relied on a dedicated G.P. employee controlling both dumpers from a remote building—a repetitive function the customer wanted to eliminate. With the system running 24/7, our parallel construction approach minimized downtime by building the complete automation solution alongside the running operation. 

The system guides untrained drivers through the entire sequence using high-visibility outdoor displays: pull forward past the back stop, wait for the automatic back stop to rise, reverse to contact, then proceed to the enclosed operator booth. The weatherproof booth includes an HMI with real-time status and instructions, an up/down joystick, and a foot pedal enable. Joystick operation automatically starts the chip conveyor system, and the 'up' command pauses if the hopper reaches capacity. The HMI also provides detailed diagnostics for GP maintenance troubleshooting. 

Cognex machine vision with machine learning identifies chip versus bark loads. Radar sensors detect truck and trailer positioning with immunity to rain and outdoor conditions. Ethernet-based inclinometers monitor each telescoping hydraulic stage for position, velocity, and rate errors throughout the operation. Each of the two dumper lanes presented unique back stop and feedback challenges requiring custom solutions. 

The upgraded system was recognized as the fastest dumper in the area. By empowering drivers to self-operate, Georgia-Pacific eliminated operator dependence, improved throughput, and enhanced safety through comprehensive monitoring and automated interlocks.