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Bianchini Oil Extraction

Control System for Soybean Oil Extraction Plant

Altus was responsible for the development and implementation of the control and supervision system for the soybean oil extraction process at the company’s facility.

The solution improved process stability, enhanced operational reliability, and optimized extraction performance, contributing to higher product quality and greater operational efficiency in the vegetable oil production chain.

Modernization of the Plant’s Control System

The system implemented at the production unit in Rio Grande, RS, comprises 10 automation panels housing 12 control columns (PNs), as well as more than 70 motor control center (CCM) columns dedicated to managing the soybean oil extraction process.

The solution supervises and controls over 3,000 I/O points across the entire production chain, from soybean drying and preparation for oil extraction to extraction, meal production, storage, and product distribution.

In addition to NX Series controllers, the complete system integrates more than 90 soft starters and PROFIBUS-networked frequency inverters, ensuring precise process control, operational stability, and high system performance throughout the plant.

Remote supervision and control

The solution enables remote supervision and operation of the plant, minimizing operational risks for the workforce

Enhanced security

Swift detection of system faults and incidents, thanks to the implementation of precise, actionable diagnostics

Multiprotocol Capability

An open architecture system, utilizing widely recognized communication protocols (Profibus-DP, HART, and Modbus TCP)

Quick decision making

The PLC’s seamless communication with field devices enhances decision-making speed for the management team

Comprehensive PROFIBUS control with full connectivity

The developed application uses 3 Profibus networks: one redundant network with remote I/O units from the NX Series, and a simple network for controlling inverters and soft starters. While the redundant network has 13 redundant remote units, the other controls the inverters and soft starters with 99 items, including 27 inverters and 72 soft starters.

The entire project encompasses 10 automation panels with a total of 13 columns (PNs). The scope of the project also included commissioning, startup, assisted operation, and training for both maintenance and operational teams.

Remote supervision and operation with BluePlant HMI/SCADA

The system relies on BluePlant HMI/SCADA software to supervise key processes such as Warehouses 2 and 3, Laminators 1 and 2, Screeners, Preparation, Flow Scales 1 and 2, Dryer, and Pier Towers.

With 83 monitoring screens, the SCADA system manages over 150 motors that drive product and raw material movement within the plant and during ship loading operations at the pier.

The software provides plant managers and operators with remote access to the system, allowing them to collaborate in real-time with field technicians, streamlining overall plant management.

High-availability with a redundancy architecture

The developed application utilizes the NX Series controllers as the central component of the unit's control system. The high technological potential of Nexto products qualifies them to operate large numbers of remote points and racks, as well as to control projects such as water treatment in a distributed and redundant manner.

The system features a redundancy setup with two NX3030 CPUs, one primary (active), responsible for real-time control, and a standby backup unit that continuously monitors the performance of the primary CPU.

In the event that a failure occurs and the primary CPU becomes unavailable, the standby equipment automatically assumes control of the process, without the need for any operator action and without causing losses to the plant operation. This switch in functions between the equipment is known as switch-over.