Project Overview

Reducing Waste with cotton seed de-oiling

In 2022, one of SGA’s client’s made a successful foray into cotton seed de-oiling as part of their waste reduction and revenue diversification strategy. This pioneering program stands out as one of the few de-oiling initiatives in Australia.

SAFEgroup Automation (SGA) was subcontracted to integrate the new de-oiling plant over a period of 14 months.

Based in Grassdale, Queensland, the client operates within the agricultural sector, driving innovation in cotton processing and waste-to-value initiatives.

SGA has an established, ongoing relationship with the client’s broader network, having previously delivered successful plant integrations and upgrades across multiple sites.

  • Ignition Perspective SCADA project for an existing Ignition gateway on site.
  • Allen Bradley Compact Guardlogix 5380.
  • Allen Bradley Point I/O remote rack.
  • Allen Bradley Control Logix remote I/O rack.
SGA’s Involvement

Integrating a New plant

The key challenge was the risk of unexpected shut-downs leading to extended downtime due to the nature of Anderson machines. SGA pro-actively tackled this by working ahead of schedule to maximise testing and simulating prior to commissioning.

  • Integrated multiple Anderson machines and supporting conveyors and pumps from Ahrens.
  • Developed mobile responsive screens, primarily for iPads, granting operators the flexibility to monitor abnormal situations while performing their regular duties.
  • Implemented equipment device logic using Allen Bradley Process Library blocks, ensuring both flexible functionality and standardised operations.
  • Included key maintenance metrics, such as runtime and number of starts, in all motors. This is to facilitate proactive maintenance planning.
  • Designed and implemented a SCADA system that provided mimics of the plant, as well as a cards-based overview for efficient operation. This SCADA system was specifically designed with abnormal situation management in mind, using colour coding to highlight and address abnormal situations.
  • Enabled user-defined trending for comprehensive analysis of both plant and equipment performance.
  • Completed the project shell months in advance and provided a demonstration/simulation to let clients pro-actively identify and address any potential issues.
  • Conducted face-to-face meetings with the client to showcase progress, discuss challenges, and ensure effective communication throughout the project.

The integration of the new cotton de-oiling plant was completed successfully, helping the client advance their sustainability and waste reduction goals. By recovering valuable oil from cottonseed, the plant now supports both environmental and economic outcomes, positioning the client as an innovator in agricultural processing.

SGA’s proactive approach to testing and simulation before commissioning ensured a smooth start-up and minimised downtime. The new SCADA system gives operators clear visibility across the plant with mobile access, intuitive controls, and detailed maintenance metrics, strengthening operational efficiency and long-term reliability.