Egypt 100K T/Y Soybean Oil Plant Automation | SENTRADO
A detailed case study of SENTRADO's industrial automation solution delivering measurable results for food processing operations in Egypt.
Project Background & Objectives
SENTRADO delivered a complete greenfield automation solution for a 100,000 tons-per-year soybean oil processing plant constructed near Alexandria, Egypt. As a new-build project with no existing control infrastructure, the client had the opportunity to implement a state-of-the-art automation system from the ground up — and they chose SENTRADO as their sole automation contractor for the entire facility.
The plant encompasses raw material receiving and storage, seed preparation, solvent extraction, oil refining, degumming, neutralization, bleaching, deodorization, and finished product packaging. The automation scope covered every motor, valve, instrument, and conveyor across all process areas, making it one of the most comprehensive automation projects SENTRADO has delivered in the Middle East and North Africa region.
Given the greenfield nature of the project, SENTRADO worked closely with the EPC (Engineering, Procurement, Construction) contractor from the design phase, providing input on instrument selection, control room layout, cable routing, and network architecture to ensure optimal integration between the mechanical, electrical, and automation disciplines.
Problems We Had to Solve
1. Greenfield Complexity
Starting from zero infrastructure meant every aspect of the automation system — from network topology to operator workstation placement — had to be designed, specified, and delivered without the benefit of existing systems or reference points.
2. Multi-Process Integration
The plant combines nine distinct process areas, each with different control requirements, response times, and safety considerations. Integrating these into a unified control platform while maintaining logical separation was a significant engineering challenge.
3. Water-Scarce Environment
Egypt's water scarcity constraints required the CIP (Clean-in-Place) system to minimize water consumption while meeting stringent food sanitation standards. Traditional CIP sequences were too water-intensive for the local context.
4. Workforce Development
The local workforce had limited exposure to industrial automation. The client required a system that was easy to learn plus a comprehensive training program that would build internal capacity for long-term operation and maintenance.
5. Hot Climate & Dust
Alexandria's coastal desert environment brings high temperatures, salt-laden humidity, and fine sand dust. All field equipment and cabinets needed protection against these corrosive and abrasive conditions.
Our Approach & System Architecture
SENTRADO engineered a fully integrated automation platform built on Siemens S7-400 controllers with ET 200SP distributed I/O, connected via a high-speed PROFINET backbone with fiber-optic redundancy. The system uses a client-server architecture with four WinCC operator stations in the central control room and two local HMI panels in the extraction and packaging areas. The network was segmented into process control, safety, and business VLANs for security and performance.
The CIP system was redesigned with water-recovery logic that captures and reuses final rinse water for the pre-rinse cycle of the next cleaning sequence, reducing freshwater consumption by approximately 40% compared to conventional CIP designs. Automated valve manifolds route cleaning solutions through the correct circuits based on recipe selection, with conductivity and temperature sensors verifying wash effectiveness before returning the system to production.
Silo management was fully automated with radar level measurement, aeration control based on grain temperature and moisture, and automated truck receiving with barcode-based lot tracking. The batch control system manages weighing, dosing, and mixing sequences with electronic batch records that provide complete genealogy from incoming soybeans to bottled oil. All field cabinets were specified with IP55 protection, stainless steel hardware, and filtered ventilation to withstand the coastal desert environment.
System Architecture Highlights
- Siemens S7-400 controllers with ET 200SP distributed I/O across 9 process areas
- PROFINET fiber-optic ring network with VLAN segmentation
- WinCC SCADA with 4 control room stations and 2 field HMIs
- Water-recovery CIP system reducing freshwater use by 40%
- Automated silo management with radar level and aeration control
- Batch control with electronic batch records and genealogy tracking
- Barcode-based raw material receiving and lot traceability
- IP55 stainless steel cabinets for coastal desert protection
System Parameters & Configuration
| Control System | Siemens SIMATIC S7-400 |
| Controllers | 2 × CPU 414-3 (redundant) + 1 safety CPU |
| Total I/O Points | 2,800+ (AI: 420, AO: 140, DI: 1,600, DO: 640) |
| Communication Protocol | PROFINET IRT / PROFIBUS DP / AS-i Safety |
| HMI / SCADA | WinCC RT Professional — 4 OS + 2 local HMI |
| Control Cabinets | 16 × IP55 stainless steel |
| Distributed I/O Stations | 22 × ET 200SP |
| CIP Sequences | 12 automated cleaning circuits |
| Power Range | 380V 3-phase, 50Hz + 24V DC control |
| Silo Capacity | 8 × 5,000-ton silos with auto management |
| Batch Records | Electronic genealogy from intake to packaging |
| Manual Intervention | 95% reduction vs. conventional plant |
Key Components & Hardware
Siemens CPU 414-3
6ES7414-3XM05-0AB0
Main process controller (redundant pair)
ET 200SP I/O
6ES7155-6AU01-0BN0
Distributed I/O with hot-swap modules
WinCC RT Professional
6AV2105-0DA06-0AA0
Central SCADA with batch option
SITRANS LR250 Radar
7ML5427-0CL00-0AC1
Non-contact silo level measurement
SIPART PS2 Positioner
6DR5210-0EG00-0AA0
Smart valve positioner for control valves
SIRIUS 3RW55 Soft Starter
3RW5534-6HA14
Reduced-voltage motor starting
Rittal HD Cabinet
HD 1680.600
Stainless steel IP55 enclosure
SCALANCE XC216 Switch
6GK5216-0BA00-2AC2
Managed PROFINET switch
Project Phases
FEED & Detailed Design
10 weeksProcess automation design, I/O lists, network plan
Panel Manufacturing
8 weeks16 cabinets built, wired, and factory tested
Software Engineering
12 weeksFull application development including CIP and batch
FAT
3 weeksComprehensive simulation with client and EPC teams
Shipping to Egypt
4 weeksOcean freight to Alexandria Port
Installation Supervision
8 weeksOn-site support during mechanical installation
Commissioning & SAT
6 weeksLoop checks, wet commissioning, performance test
Training & Handover
3 weeksClassroom and hands-on operator training
Measurable Outcomes
Performance data verified after system commissioning and sustained operation.
Near-fully automated operation
CIP water recovery system
Complete genealogy for food safety
Zero recordable incidents during commissioning
Before vs After: Quantified Comparison
| Metric | Before | After | Change |
|---|---|---|---|
| Manual intervention | High (operator-dependent) | 95% automated operation | −95% |
| CIP water usage | Baseline (once-through) | 40% savings via recovery | −40% |
| Batch traceability | Manual logbooks | 100% digital genealogy | Full trace |
| Safety incidents | Risk during commissioning | 0 recordable incidents | Zero |
| Commissioning time | Industry average 8–12 months | Completed on schedule | On time |
Data based on project commissioning reports and sustained operational measurements. Client name available under NDA.
Bottom Line Impact
The delivered automation system exceeded all performance targets specified in the contract, achieving higher throughput, lower energy consumption, and improved product quality compared to the baseline operation. The client reported full return on investment within the projected payback period and has since engaged SENTRADO for additional plant expansion phases.
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