Rapid Recovery: Helping Ardent Mills Bounce Back After Hurricane Milton
In early October 2024, Hurricane Milton swept through Florida, leaving a trail of destruction in its wake. Among the areas impacted by the Category 3 storm was the Ardent Mills facility in Gibsonton, Florida, just south of Tampa. Although the plant avoided catastrophic damage, the storm’s high winds knocked over a key programmable logic controller (PLC) panel on the roof of the storage silos. Recognizing the urgency of the situation, Interstates quickly mobilized a team to repair the damage, ensuring the facility could resume operations as quickly as possible.
Proactive Planning and Rapid Response
The Interstates team had already established a strong partnership with Ardent Mills through previous projects, including the construction of the Gibsonton facility. This relationship proved crucial when Hurricane Milton approached. Interstates was contacted about 24 hours before the hurricane made landfall to assist with disaster preparedness and recovery planning. “We backed up all the programs that run the facility to prepare for potential data recovery needs,” says Bryan Monroe, Automation Manager at Interstates. “Our team also held an internal meeting to outline how we would respond if damage occurred.”
After the hurricane passed, the damage assessment revealed that a critical PLC control panel had been knocked over, damaging conduits, wires, and fiber optic cables. Once alerted, Interstates immediately activated its recovery plan. Within hours, electricians had loaded their trucks with materials and hit the road. Meanwhile, Interstates’ control engineering team identified and procured the necessary components, ensuring the timely delivery of replacement parts. “The speed and coordination of our team were impressive,” says Jake Ten Haken, Vice President of Client Delivery. “We had a crew on-site early Saturday morning, less than two days after receiving the initial call.”
Efficient Repairs and Restoration
Upon arrival at the facility, the Interstates crew collaborated with the Ardent Mills team to diligently repair the damage. This involved rebuilding the PLC panel’s legs, re-terminating wires, replacing damaged fiber optics, and thoroughly testing all components. Remote support from Interstates’ programming team expedited the process by validating the repaired systems.
“Within two days, we had the plant’s power back online, and by day five, the control panel was fully operational,” Monroe says. “The team’s dedication over the weekend was remarkable, and it showcased the depth of expertise across all our disciplines.”
The ability to respond quickly and effectively was due in part to the strong communication channels between Interstates and Ardent Mills. “Daily touchpoints via Teams allowed us to stay aligned, share progress updates, and troubleshoot challenges in real time,” Ten Haken explains. “This level of collaboration ensured we could meet the client’s expectations and swiftly get the facility back in production.”
Lessons Learned and Future Preparedness
The post-storm recovery effort underscores the importance of proactive disaster planning. The Gibsonton facility, constructed with hurricane resilience in mind, held up well overall. Moving forward, Ardent Mills plans to reinforce the legs of rooftop control panels and continue conducting regular generator testing to mitigate future risks.
“This facility was built to withstand severe weather, and it performed admirably under the circumstances,” says Monroe. “The lessons learned here will only enhance the site’s readiness for future events.”
Commitment to Excellence
The Hurricane Milton recovery project exemplifies Interstates’ ability to combine technical expertise with a client-focused approach. The team’s readiness to adapt, act quickly, and deliver results made a tangible difference for Ardent Mills. “We’re proud of the role we played in supporting Ardent Mills during a challenging time,” says Ten Haken. “Our team’s willingness to go above and beyond reflects the values we bring to every project.”
Dean Hoerning, Senior Director of Engineering at Ardent Mills, shares his thoughts about the recovery project: “We’re grateful for Interstates’ quick reaction at our Port Redwing plant to help support us after Milton. It is always great to see the partnership, control system support, experience, and knowledge of your support team. I want to give a special call out to Andy Hammer and Bryan Monroe. Having them here was just like having an extension to the Ardent Mills team.”
As Florida continues to recover from Hurricane Milton, the Gibsonton facility demonstrates the resilience of both the infrastructure and the partnerships that made its restoration possible. For Interstates, this project is another example of how a combination of preparation, expertise, and teamwork can effect positive change even during a disaster.