Increasing Yield & Reducing Energy Losses in an Ammonia Production Plant
- Fertilizer Production
- Mid-sized manufacturer operating a 20-year-old ammonia plant
- North Africa
Automating Repetitive Operations and Reducing Manual Errors in a Chemical Blending Facility
- Specialty Chemicals Manufacturing
- Chemical blending and packaging facility in Egypt
- Automating repetitive operations and reducing manual errors
Obstacles Our Experts Have Transformed into Opportunities
A specialty chemical blending and packaging facility was dealing with growing product complexity—but still relied heavily on manual workflows:
Manual Recipe Adjustments
Blend recipes were manually adjusted based on lab feedback, leading to inconsistent quality across batches
Excessive Manual Data Entry
Operators spent 25–30% of their time on data logging and manual report generation
Batch Record Inaccuracies
Batch records were error-prone and triggered repeated audit findings from customers
Spreadsheet-Based Scheduling
Scheduling of blending, cleaning, and packaging cycles was managed on spreadsheets, causing frequent clashes and delays
No Automated Change Communication
Any change in raw material or packaging line required manual communication across departments
Manual Systems Blocking Growth
The business was growing—but its systems weren’t keeping up. Human-driven tasks were becoming bottlenecks.
Teec’s Expert-Led Solution
TEEC deployed its Intelligent Automation Advisory service to streamline and digitize operations using fit-for-purpose automation:
What Our Experts Did
Identified and prioritized high-value automation targets through a Digital Process Mapping (DPM) workshop
Designed a modular control strategy to automate batch adjustments based on real-time lab data
Implemented a low-code workflow automation platform to generate digital batch records, compliance logs, and shift reports
Integrated scheduling automation for batch, CIP, and packaging lines—enabling visibility and clash prevention
Trained staff to operate and continuously improve new automated workflows using visual logic and exception handling
TEEC delivered scalable automation—without requiring expensive control system overhauls.
Execution Approach by Teec’s Experts
TEEC deployed a targeted automation advisory program with minimal disruption and high return:
- Conducted a plant-wide audit to identify repetitive, error-prone, and time-intensive manual tasks
- Prioritized automation use cases based on ROI, feasibility, and compliance risk (e.g., batch records, CIP scheduling, lab feedback loops)
- Developed a modular automation architecture using low-code and platform-agnostic tools
- Designed AI-assisted blending logic integrated with lab testing data for in-process adjustments
- Automated shift reporting, batch traceability, and cleaning cycles with integrated scheduling logic
- Integrated automation workflows with existing PLC/SCADA systems and MES where applicable
- Implemented secure data pipelines and audit trails for all automated activities
- Conducted User Acceptance Testing (UAT) with operators and process engineers to refine logic and workflows
- Created SOPs, escalation logic, and exception-handling workflows
- Trained frontline operators, control room staff, and supervisors through scenario-based sessions
- Launched a dashboard for tracking manual vs. automated task ratio and adoption rates
Results & Impact
Reduced data entry and reporting time by 92%, saving 350+ man-hours per month
Improved blending consistency by 17%, enhancing product quality and batch reliability
Shift leaders reported 40% fewer handover errors due to automated schedule alignment
Enabled operators to focus on value-added tasks by automating routine, repetitive operations
Integrated Value Through Teec’s Data-Driven Solutions
Operational Excellence Implementation (BPM Solutions)
