Industrial Automation Case Studies
Proven results across food processing, water treatment, mining, building automation and more. Real projects, real outcomes for global clients.
500+
Projects Completed
25+
Years Experience
10+
Countries Served
100%
On-time Delivery
12 Key Industrial Automation Projects
From 6,000 T/D soybean oil plants in Brazil to water treatment facilities in Indonesia — see how we deliver measurable results across industries and continents.
Food ProcessingBrazil
Brazil 6,000 T/D Soybean Oil Processing Automation
Large-scale soybean crushing and oil extraction plant requiring complete DCS automation.
Brazil 6,000 T/D Soybean Oil Processing Automation
Large-scale soybean crushing and oil extraction plant requiring complete DCS automation.
Customer Challenge
Outdated control system limiting production efficiency and causing frequent unplanned downtime in a 6,000 T/D continuous operation plant.
Solution Provided
Complete DCS automation system built on Siemens PCS7 platform with redundant control architecture designed for 24/7 operation in tropical climate.
Technical Details
200+ I/O points, redundant PROFIBUS network, real-time recipe management, automated temperature and pressure control loops for crushing and extraction processes.
Equipment Used
- Siemens SIMATIC S7-400
- Siemens PCS7 DCS
- ET200PA distributed I/O
- WINCC SCADA system
- 200+ I/O points
Project Result
30% increase in production throughput with 99.5% system availability.
Food ProcessingTurkey
Turkey 4,000 T/D Oil Processing Plant Automation
Multi-grade edible oil production requiring integrated process control.
Turkey 4,000 T/D Oil Processing Plant Automation
Multi-grade edible oil production requiring integrated process control.
Customer Challenge
Need for full automation across pretreatment, extraction, and refining processes with multi-grade recipe management capability.
Solution Provided
Integrated temperature, pressure, and flow control loops with recipe management system supporting rapid changeover between product grades.
Technical Details
Multi-stage temperature profiling, automated solvent recovery, real-time quality monitoring with PID cascade control for critical parameters.
Equipment Used
- Siemens SIMATIC S7-400
- ET200PA distributed I/O
- WINCC SCADA system
- PROFIBUS DP network
Project Result
35% production efficiency improvement and 15% energy savings achieved.
Food ProcessingEgypt
Egypt 100,000 T/Y Greenfield Soybean Oil Plant
Complete greenfield automation from raw material handling to packaging.
Egypt 100,000 T/Y Greenfield Soybean Oil Plant
Complete greenfield automation from raw material handling to packaging.
Customer Challenge
Greenfield project requiring end-to-end automation of a 100,000 T/Y soybean oil plant with no existing infrastructure.
Solution Provided
Complete process automation covering silo management, batch control, CIP system automation, and finished product packaging lines.
Technical Details
Automated silo level management, precise batch weighing and dosing, CIP cleaning automation with recipe-driven sequences, integrated material tracking.
Equipment Used
- Siemens SIMATIC S7-400
- ET200SP distributed I/O
- WINCC SCADA
- Automated valve control
Project Result
95% reduction in manual intervention with fully automated operation.
Food ProcessingBrazil
Louis Dreyfus PLC Upgrade Project
Legacy PLC migration to modern high-availability Siemens platform.
Louis Dreyfus PLC Upgrade Project
Legacy PLC migration to modern high-availability Siemens platform.
Customer Challenge
Aging PLC systems on active oil processing lines risked obsolescence failures and lacked modern connectivity.
Solution Provided
Phased migration to Siemens S7-400 HA platform with zero unplanned downtime during switchover, maintaining full production continuity.
Technical Details
1:1 signal mapping, hot-swap I/O modules, HA redundancy with 1:1 switchover, parallel operation during commissioning to ensure zero production loss.
Equipment Used
- Siemens SIMATIC S7-400 (HA)
- ET200SP HA
- STEP 7 programming
- WINCC SCADA
Project Result
Zero unplanned downtime post-upgrade with 30% faster recipe changeover.
Food ProcessingBrazil
Bunge Control System Migration
Complete legacy ICS to Siemens PCS7 DCS migration.
Bunge Control System Migration
Complete legacy ICS to Siemens PCS7 DCS migration.
Customer Challenge
Legacy ICS at end-of-life needed complete replacement with modern DCS platform while maintaining continuous soybean processing operations.
Solution Provided
Full engineering, procurement, and commissioning of Siemens PCS7 DCS platform including operator training and documentation handover.
Technical Details
Complete I/O migration, function block reengineering, historian data integration, sequential switchover strategy maintaining production continuity.
Equipment Used
- Siemens PCS7 DCS
- SIMATIC S7-400
- ET200SP HA
- PCS7 OS engineering
Project Result
Seamless migration with full production continuity and improved data integrity.
Food ProcessingChina
COFCO 5,000 T/D Oilseed Processing Automation
Integrated automation for oilseed pre-treatment, extraction, and refining.
COFCO 5,000 T/D Oilseed Processing Automation
Integrated automation for oilseed pre-treatment, extraction, and refining.
Customer Challenge
Need for integrated automation covering 5,000 T/D pre-treatment and extraction plus 1,000 T/D refining with full food safety traceability.
Solution Provided
Unified SCADA platform with real-time monitoring, alarm management, and production data historian ensuring complete batch traceability.
Technical Details
SMART+ redundancy architecture, integrated alarm management system, production data historian with 3-year retention, automated recipe execution.
Equipment Used
- Siemens SIMATIC S7-400 (SMART+)
- ET200PA
- WINCC OA
- Production data historian
Project Result
25% increase in oil yield with full food safety traceability compliance.
Water TreatmentIndonesia
Indonesia Water Treatment Plant Automation
Aging infrastructure modernization with remote monitoring capability.
Indonesia Water Treatment Plant Automation
Aging infrastructure modernization with remote monitoring capability.
Customer Challenge
Aging infrastructure with obsolete control equipment needed complete modernization while maintaining continuous water supply to the region.
Solution Provided
PLC-based SCADA system with remote monitoring allowing centralized oversight of all treatment stages including filtration, dosing, and distribution.
Technical Details
Automated chemical dosing control, real-time water quality monitoring, VFD pump optimization, remote HMI access via secure web interface.
Equipment Used
- Siemens SIMATIC S7-1500
- WinCC SCADA
- VFD panels
- Remote I/O stations
Project Result
99.5% system uptime achieved with 50% reduction in on-site operator requirements.
Building AutomationSaudi Arabia
Saudi Arabia Building Automation System
Large commercial complex requiring integrated BMS.
Saudi Arabia Building Automation System
Large commercial complex requiring integrated BMS.
Customer Challenge
Large commercial complex with multiple buildings requiring unified building management system for HVAC, lighting, and energy monitoring.
Solution Provided
Centralized BMS with DDC controllers integrating HVAC, lighting control, and energy metering into a single management platform.
Technical Details
BACnet/IP protocol integration, scheduled HVAC optimization, occupancy-based lighting control, energy consumption analytics dashboard.
Equipment Used
- Siemens DDC controllers
- BACnet/IP controllers
- HVAC integration modules
- Central BMS workstation
Project Result
25% energy savings with unified management across all building systems.
MiningSouth Africa
South Africa Mining Conveyor Automation
Harsh mining environment requiring robust and redundant control.
South Africa Mining Conveyor Automation
Harsh mining environment requiring robust and redundant control.
Customer Challenge
Harsh dust, vibration, and temperature conditions causing frequent control system failures in critical conveyor operations.
Solution Provided
IP65-rated PLC cabinets with redundant control architecture and vibration-resistant components designed for extreme mining conditions.
Technical Details
IP65 protection rating, redundant CPU configuration, belt speed synchronization, belt slip detection, emergency stop chain integration.
Equipment Used
- Siemens SIMATIC S7-1500
- IP65 rated cabinets
- HMI panels (IP65)
- VFD drives
Project Result
Zero unplanned downtime in 6 months of continuous mining operation.
ManufacturingVietnam
Vietnam Manufacturing Line Upgrade
Legacy system replacement with modern PROFINET network.
Vietnam Manufacturing Line Upgrade
Legacy system replacement with modern PROFINET network.
Customer Challenge
Legacy control system incompatible with modern industrial protocols, preventing integration with MES and limiting production visibility.
Solution Provided
Complete PLC migration to Siemens S7-1200 with PROFINET network backbone, enabling seamless MES integration and real-time production monitoring.
Technical Details
PROFINET IRT for motion control, OPC UA data exchange with MES, HMI recipe management, barcode-based product tracking integration.
Equipment Used
- Siemens SIMATIC S7-1200
- PROFINET switches
- HMI touch panels
- OPC UA gateway
Project Result
40% faster production cycle with full MES integration and real-time OEE tracking.
Data CenterUnited Arab Emirates
UAE Data Center MCC Panel & Automation
Tier III data center requiring high-reliability MCC with redundant PLC and 99.99% power availability.
UAE Data Center MCC Panel & Automation
Tier III data center requiring high-reliability MCC with redundant PLC and 99.99% power availability.
Customer Challenge
Tier III data center required concurrently maintainable MCC with 40+ motor circuits, redundant control, and zero single points of failure for 99.99% cooling availability.
Solution Provided
Form 4b withdrawable MCC with Siemens S7-1500R redundant PLC, dual PROFINET rings, SIMOCODE motor protection, and VFD bypass for critical cooling pumps.
Technical Details
4,000A MCC rating, 42 motor circuits (5.5–132kW), dual PROFINET A/B rings with MRP, BACnet/IP and SNMP DCIM integration, PUE monitoring, VFD auto-bypass.
Equipment Used
- Siemens S7-1500R redundant CPU
- SIVACON S8 Form 4b MCC
- SIMOCODE pro V PN (×42)
- ABB ACS880 VFDs with bypass
Project Result
99.99% power availability achieved with 30% energy efficiency improvement and zero single points of failure.
Water TreatmentNigeria
Nigeria VFD Pump Station Automation
Municipal water pump station with 6×250kW VFD pumps, solar hybrid power, and remote SCADA monitoring.
Nigeria VFD Pump Station Automation
Municipal water pump station with 6×250kW VFD pumps, solar hybrid power, and remote SCADA monitoring.
Customer Challenge
Six 250kW direct-on-line pumps causing water hammer, high energy costs, and frequent mechanical failures at a remote municipal pump station with unreliable grid power.
Solution Provided
VFD control for all six pumps with constant-pressure algorithm, S7-1200 PLC, 500kWp solar hybrid system, 4G LTE remote SCADA, and multi-stage surge protection.
Technical Details
6× ABB ACS880 (250kW), 30-second soft-start/stop ramps, automatic pump staging and rotation, 500kWp solar PV with ATS, 4G VPN remote access, Class I/II/III surge protection.
Equipment Used
- Siemens S7-1200 CPU 1214C
- 6× ABB ACS880 VFD (250kW)
- WinCC SCADA with 4G LTE
- DEHNventil surge protection
Project Result
40% energy reduction, 50% fewer site inspections, zero water hammer events, and 80% less generator runtime.
"Why SENTRADO? Because they delivered our 6,000 T/D soybean oil plant automation on time, with zero unplanned downtime in 18 months of operation. Their Siemens engineering team knows the process inside out."
— Operations Director, Major Brazilian Oil Processor
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