Turkey 4,000 T/D Oil Processing Automation | SENTRADO
A detailed case study of SENTRADO's industrial automation solution delivering measurable results for food processing operations in Turkey.
Project Background & Objectives
A leading Turkish edible oil producer commissioned SENTRADO to deliver a comprehensive process automation system for their 4,000 tons-per-day multi-seed oil processing plant in the Marmara region. The facility processes sunflower, corn, canola, and cottonseed oils across pretreatment, extraction, and refining lines, requiring flexible automation that could handle rapid product grade changeovers without compromising quality or throughput.
The client's strategic objective was to establish one of the most technologically advanced oil processing facilities in the Middle East and Eastern Europe. They needed an automation partner with deep process knowledge in vegetable oil refining and the engineering capability to deliver a system that integrated seamlessly with their existing mechanical equipment and third-party packaging lines.
SENTRADO was selected after a competitive bidding process based on our proven track record with similar-scale oil processing projects, our in-depth expertise with Siemens process control systems, and our ability to provide comprehensive after-sales support including remote diagnostics and on-site response within 48 hours.
Problems We Had to Solve
1. Multi-Grade Production Complexity
The plant produces over 20 different oil grades across four seed types. Each grade requires different temperature profiles, pressure settings, and chemical dosing parameters. The existing manual changeover process took 2-3 hours and generated significant off-spec product during transitions.
2. Energy Intensive Refining Process
The deodorization and physical refining sections consume enormous amounts of thermal energy. The client needed precise control of heating and cooling cycles to reduce steam consumption while maintaining product quality parameters such as free fatty acid content and color.
3. Solvent Recovery Efficiency
In the extraction section, hexane solvent recovery is both an economic and environmental imperative. Poor control of the evaporation and condensation system was resulting in excessive solvent losses exceeding industry benchmarks.
4. Regulatory Compliance
Turkish food safety regulations (aligned with EU standards) require complete batch traceability from raw material intake through finished product. The existing system lacked the data logging and reporting capabilities needed for audit compliance.
5. Skilled Operator Shortage
The region faced a shortage of experienced DCS operators. The client required an HMI system so intuitive that newly trained operators could achieve full competency within two weeks.
Our Approach & System Architecture
SENTRADO implemented an integrated control system based on Siemens S7-400 controllers with ET 200PA distributed I/O, networked over a redundant PROFIBUS DP backbone. The system architecture was organized into three process-cell controllers — pretreatment, extraction, and refining — each with dedicated I/O and autonomous operation capability while sharing production data through the WinCC SCADA platform.
The centerpiece of the solution was an advanced recipe management system that automated product grade changeovers. Operators select the target grade from a pre-configured recipe library, and the system automatically adjusts temperature setpoints, valve positions, pump speeds, and chemical dosing rates according to a validated sequence. This reduced changeover time from 2-3 hours to under 30 minutes and virtually eliminated off-spec production during transitions.
Energy optimization was achieved through model-based control of the deodorization section. Advanced PID cascade loops precisely control the stripping steam injection based on real-time free fatty acid measurements, while heat recovery loops transfer thermal energy between outgoing hot oil and incoming cold oil. The solvent recovery system uses pressure-compensated temperature control across the multi-effect evaporator train, maximizing hexane condensation while minimizing cooling water usage. The SCADA system includes a full batch traceability module that records every process parameter for each production batch, generating compliance reports in Turkish and English.
System Architecture Highlights
- Siemens S7-400 controllers with ET 200PA distributed I/O
- Redundant PROFIBUS DP network with fiber-optic segments
- Advanced recipe management with 20+ automated product grade profiles
- PID cascade control for deodorization temperature and steam injection
- Automated solvent recovery with multi-effect evaporator control
- WinCC SCADA with batch traceability and compliance reporting
- Heat recovery optimization loops reducing steam consumption
- Multi-language HMI (Turkish and English)
System Parameters & Configuration
| Control System | Siemens SIMATIC S7-400 |
| Controllers | 3 × CPU 414-3 (process-cell dedicated) |
| Total I/O Points | 2,400+ (AI: 320, AO: 120, DI: 1,400, DO: 560) |
| Communication Protocol | PROFIBUS DP / PROFINET / Modbus RTU |
| HMI / SCADA | WinCC RT Professional — 3 OS + 1 EWS |
| Control Cabinets | 8 × IP54 with thermal management |
| Distributed I/O Stations | 14 × ET 200PA |
| Recipe Profiles | 20+ automated product grades |
| Power Range | 400V 3-phase, 50Hz |
| Data Logging | Batch historian with 5-year retention |
| Changeover Time | <30 minutes (reduced from 2-3 hours) |
| System Availability | 99.7% |
Key Components & Hardware
Siemens CPU 414-3
6ES7414-3XM05-0AB0
High-performance process controller
ET 200PA I/O
6ES7650-0PH00-0AB0
Distributed I/O for field mounting
WinCC RT Professional
6AV2105-0DA06-0AA0
SCADA runtime with batch option
SITRANS TH300
7NG3212-0AN00
Temperature transmitter for refining
SITRANS P320
7MF0300-1TE01-5AF2
Pressure transmitter for extraction
MICROMASTER 440 VFD
6SE6440-2UD33-0EA1
Variable frequency drive for pumps
Rittal AX Cabinet
AX 1318.000
Stainless steel hygienic enclosure
SIRIUS Safety Relay
3SK1211-1BB40
Emergency stop safety circuit
Project Phases
Front-End Engineering
6 weeksProcess analysis, control philosophy, I/O scheduling
Panel Manufacturing
5 weeksCabinet build, wiring, factory testing
Software Development
8 weeksPLC programming, HMI, recipe system, reports
FAT
1 weekIntegrated system test with client engineers
Shipping to Turkey
3 weeksSea freight from Shanghai to Istanbul
Site Commissioning
5 weeksInstallation, loop checks, startup, SAT
Training & Support
OngoingOperator training, 12-month warranty support
Measurable Outcomes
Performance data verified after system commissioning and sustained operation.
Overall equipment effectiveness increase
Steam and electricity consumption reduced
From 2-3 hours to under 30 minutes
Continuous operation since commissioning
Before vs After: Quantified Comparison
| Metric | Before | After | Change |
|---|---|---|---|
| Overall equipment effectiveness | Baseline OEE | 35% improvement | +35% |
| Energy consumption | Baseline | 15% reduction (steam + electricity) | −15% |
| Changeover time | 2–3 hours | Under 30 minutes (85% faster) | −85% |
| System uptime | ~94% (aging PLCs) | 99.7% since commissioning | +5.7 pts |
| Production visibility | Shift-end reports | Real-time dashboards | Live data |
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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