Automated Pilot Plant Increases Production by 60 Percent for Leading Automotive Chemicals Company

EPIC Systems successfully transformed a leading automative chemicals company’s petroleum additive production with a fully automated, scalable pilot plant, enhancing efficiency, consistency, and formulation capabilities while accelerating deployment and future expansion potential. 

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Hygienic Process System Design

Project

Overview

  • Industry: Energy (Oil & Gas) 
  • Location: USA
  • Customer Use Case: Batch Mixing & Blending

Customer’s

Challenge

A leading automotive chemicals company sought to upgrade its petroleum additive production system from a manual process to a fully automated operation. The existing system lacked consistency in batch production, making it difficult to ensure quality across multiple runs.  

 

Additionally, the company needed enhanced formulation flexibility for both internal testing and end-customer customization. The previous equipment’s temperature limitations also restricted the development of future products. To meet growing demand, the company aimed for a significant increase in production capacity while maintaining stringent quality standards. 

Epic

Solution

EPIC Systems designed and delivered a custom pilot plant featuring an advanced automation integration plan. The system incorporated: 

 

  • Automated Batching & Batch Management Software: Improved consistency and tracking of process parameters across runs. 
  • DeltaV Distributed Control System: Provided seamless automation software for recipe management and real-time data collection. 
  • Higher Temperature-Rated Equipment: Enabled the development of a broader range of petroleum additive formulations. 
  • Modular Design: Allowed for faster fabrication, pre-assembled testing, and efficient delivery. 

 

The pilot plant was designed for scalability, allowing the company to expand operations as needed. EPIC’s engineering team ensured a seamless transition to automation, optimizing the plant for both increased production rates and future product development. 

Project

Impact

  • 60% Increase in Production Efficiency: Automation improved throughput while maintaining high-quality standards. 
  • Enhanced Batch Consistency & Process Monitoring: Real-time data collection and automated batching ensured uniformity and traceability. 
  • Expanded Formulation Capabilities: The system supports both internal testing and customized formulations for end customers. 
  • Higher Temperature Capabilities: Upgraded equipment enables the development of a wider range of petroleum additive formulations. 
  • Faster Deployment & Scalability: Modular design and pre-shipment FAT testing allowed for delivery within eleven months, with room for future expansion. 

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EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

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