Projects Flagship Case Study

Automated Olive Seed Handling System

A custom-engineered automation project that eliminated manual handling, reduced operating cost, and preserved food safety compliance.

Scope: Design & Build Tech: Tubular Chain Conveyor Sector: Food Processing

The Challenge

The client operated a food processing factory producing olive-based products. Olive seeds were discharged from processing machines in the basement, creating a major logistical and hygiene bottleneck.

  • Manual handling by multiple workers per shift.
  • Continuous forklift operation inside the factory.
  • High labor cost across 24-hour operation.
  • Significant hygiene and food safety risks.
"The existing process was costly, labor-intensive, and incompatible with modern food safety best practices."

Project Objectives

The goal was to transform a manual waste disposal task into a fully automated, revenue-generating process.

Eliminate Manual Handling

Remove workers and forklifts from the process entirely.

Strict Hygiene

Ensure food safety compliance with enclosed transport.

Commercial Value

Enable accurate weighing for commercial sale of by-products.

Direct Loading

Transfer directly to trucks without intermediate storage.

Engineered Solution

Scope & Responsibility

Process Engineering

Analysis of material flow and hygiene requirements.

  • By-product analysis
  • Routing design
  • Technology selection

Fabrication

Custom manufacturing of specialized equipment.

  • Tubular chain conveyor
  • 30-ton storage tank
  • Z-type loading conveyor

Automation

Smart control for variable production rates.

  • VFD motor control
  • Integrated weighing
  • Flow optimization

Integration

Installation within an active production facility.

  • Live plant install
  • Civil coordination
  • Commissioning

Engineering Challenges Solved

Challenge 1

Hygiene & Contamination

Moving organic by-products from a basement production area without dust, spillage, or cross-contamination.

Our Solution:

We selected and fabricated a fully enclosed tubular chain conveyor system, ensuring zero exposure to the factory environment.

Challenge 2

Long Distance Routing

Transporting material over approx. 100 meters with significant elevation changes while maintaining stable flow.

Our Solution:

Custom-designed conveyor geometry with precise drive speed control ensured reliable transport without clogging or segregation.

Challenge 3

Commercial Accuracy

The by-product was sold to external customers, requiring accurate weighing to turn waste into revenue.

Our Solution:

We integrated a load-cell-based weighing system directly into the 30-ton storage tank for precise, commercial-grade measurement.

System Architecture

Production Machines

Basement Level

Collection Conveyor

Under-Machine Extraction

Tubular Chain Conveyor

~100m Enclosed Transport

30-Ton Storage Tank

With Water Spray & Weighing

Z-Type Conveyor

Elevated Discharge

Direct Truck Loading

Commercial Weighing & Dispatch

Impact & ROI

Operational

  • Manual handling eliminated
  • Forklift traffic removed
  • Continuous 24/7 operation

Commercial

  • Major labor cost reduction
  • Faster disposal turnover
  • Commercial product weighing

Safety & Hygiene

  • Improved food safety
  • Cleaner factory floor
  • Reduced worker injury risk

Total Project Value: approx. 2 million EGP — Payback achieved through labor and efficiency savings.

Why This Is A Flagship Project

This project proves our strength in problem-driven engineering. It demonstrates our ability to solve complex operational problems in active food factories, integrate mechanical and automation systems, and transform a cost center into a controlled, revenue-ready process.

Modernize Your Operations

If your facility faces manual handling, hygiene risks, or operational inefficiencies, we can design a custom engineered solution to transform your performance.

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